WORK STUDY

Introduction Work study is not a new concept. Since the beginning of human race, there had always been a tendency to improve the work technique. However, this was recognized as a scientific technique much later with the efforts of some proving work by .W. !aylor, ranch " #ilberth, Henry #ault $ others. Work study is now recognized as a management technique to improve the activities in the production. It deals with the techniques of %ethod study $ work measurements, which are employed to ensure the best possible use of human, machine $ material resources in carrying out a specified activity. &b'ectives(Importance Work study is a service to management $ is aimed to achieve the following activities) *. It is a means for raising productivity of an organisation(plant by re+organisation of the work involving little or no capital e,penditure at all. -. It is used to determine the standards of performance on which effective planning $ control can be done. .. It follows a systematic approach which ensures that no related factor is over looked. /. It results in better work place layout, neat $ clean work environment resulting in minimum movement of men $ material. 0. It results in better use of human $ material resources by increasing output $ reducing waste. 1. 2esults in unnecessary human movements. 3. 4rovides better safety. 5. 2educes health hazards. 6. %inimize unit cost of production by proper selection of machines, processes etc. *7.
WORK STUDY Method Study to improve methods of production Work me surement to ccess hum n effective uses

Higher Productivity

METHOD STUDY

8%ethod Study is the systematic recording $ critical e,amination of e,isting $ proposed ways of doing work as means of developing $ applying easier $ more effective methods and reducing costs.9 !he underlying philosophy of method study is the continuing need for analyzing e,isting methods with a view to replacing them by better ones which may have come about due to technological developments. !he slogan of method study is+ 8!here is always a better way of doing things.9 "asic 4rocedure(Steps involved in %ethod Study !he basic procedure for the method study or the steps involved is as follows) *. Select) !he work to be done. -. 2ecord) :ll the relevant facts of the present or proposed method by observation or analysis. .. ;,amine) !he recorded facts critically and challenge everything that is done considering) :. !he purpose of activity. ". Where it is performed. <. !he sequence in which it is done. =. !he person who is doing it. ;. !he means by which it is done.

/. =evelop) !he most practical, economical and effective method considering all the circumstances. 0. =efine) !he new method so that it can always be identified. 1. Install) !he new method as standard practice. 3. %aintain) !he standard practice by routine cheeks.

S;>;<! ?Selection of work for study@ While selecting the work, keep the following factors in mind)+ *. ;conomic <onsideration It may be waste of time to start or to continue a long constipation if the economic importance of the 'ob is small. &2

If the 'ob is going to run for a short duration, the priority choices would be one of the following)+ a. "ottlenecks which hold up production. b. %ovement of materials over long distances between shops. c. &perations involving a great deal of manpower $ equipment. d. Highly hazardous work.

-. !echnical <onsideration It is important to make sure that adequate technical knowledge is avoidable to solve the problem. .. Human 2eactions %ental(emotional reactions to investigation must be anticipated and taken care of. %ethod Study may be more readily accepted by workers if it improves the working conditions of the worker, reduces their effort $ failure $ helps to increase these wages.

M!THOD STUDY Se"ect the #o$ to %e Studied Record f cts re" ting to e&isting method (h rt Mode" s s !& mine "" re"ev nt f cts critic ""y $ut imp rti ""y Purpos e P" ce Se'uenc e Perso n Me ns ;conomic consideration !echnical consideration Human consideration

Di gr m s

Deve"op "tern tives to the e&isting method To chieve improved f ctory nd +ork p" the ce "most yout improved Se"ect design of e'uipment economic " method) $etter nd +orking define it the ne+reduction M int conditions in method of f tigue improved use of tion m teri " *nst "" the ne+ method verify its imp"ement p" nt) e'uipment P" n, rrr interv nge, nd t regu" "sm npo+er

Higher Productivit

VARIOUS TYPES OF ASSOCIATED CHARTS OR RECORDING TECHNIQUES

:ccording to the nature of 'ob being studied and the purpose for which the record is required, the following are the most generally used techniques.

Process Charts
: chart may be a diagram, a picture or a graph which gives an overall view of a process. It helps visualizing various possibilities of alteration or improvement. : chart representing a process is called the Process Chart. : process chart records graphically or diagrammatically, in sequence the various operations connected with a person. !he process is prepared with the help of symbols and this helps in better understanding and e,amining the process with a view to improving the same.

Process Chart S !"o#s

;vents *. &peration Symbols =escriptions &peration represents an action e.g. culling a bar or driving a nail.

-. Storage .. !emporary Storage /. !ransport 0. Inspection

2epresents a slope when a finished product or a raw material awaits an action e.g. milling cutters lying in tool storage or raw material lying in storage. =elay occurs when something stops the process and a producer waits for ne,t event. It is a temporary halt in the process. ;.g. power failure, waiting for lift or a traffic 'am. Indicates the movement of an item process one location to another. !hey may be material, equipment. :n act of checking for corrections of quantity or quality of the items. Symbols of <ombined :ctivities :rticle being painted while being transported or a conveyor belt. 4owder milk item being weighted, Inspected while it is being filled ?operation@.

1. &perations cum !ransportation 3. Inspection cum &peration

T $es o% Charts
*. &utline 4rocess <hart. -. low 4rocess <hart+%ain type, %aterial type and ;quipment type.

.. !wo handed 4rocess <hart. /. %ultiple :ctivity <hart. 0. !ravel <hart.

T $es o% D&a'ra!s
*. low =iagrams. -. String =iagrams. .. <ycle #raphs. /. <hronocycle graph.

O(t#&)e Process Chart

a. It surveys and records an overate picture of the process and states only main events or steps sequence wise.

b. <onsiders only main operations and inspections, and therefore makes use of only two symbols. c. It is the first step for beginning of a detailed analysis.

CHANGING REFI** OF A +A** POINT PEN ,OUT*INE PROCESS CHART-

. / 0 2 3 1 -

Anscrew <ap Anscrew neck 2emove the old refill :ssemble the spring on new refill 4lace the new refill with spring in the barrel Screw the neck Screw the cap <heck if the ball pen writes ?Inspection@

F#o. Process Chart

It is a detailed version of outline process. It sets out sequence of flow records using symbols, marks distance travelled $ time taken on compiling an activity. !hree types) *. -. .. low 4rocess <hart ?%an@ low 4rocess <hart ?;quipment@ low 4rocess <hart ?%aterial@

4< ?%an@ + 2ecords the activities of an operator i.e. what he does. 4< ?;quipment@ B 2ecords the manner in which equipment is used. 4< ?%aterial@ B 2ecords what happens to the material i.e. changes the material goes through in location or condition.

Part o% Process Chart ,Mater&a# Chart- Sho.&)' %#o. o% $ro/(ct

SD%"&>S :<!ICI!D
&peration Inspiration storage =elay !ransport

=istances !ime %oved ?%inutes@ ?%eter@

2emarks

<asting lying industry store %oves to gas cutting machine Wait, cutting machine being set 2aising out Wait for trolley %oved to machine shop Inspected before machining *7 + + + -7 + . 0 -7 *7 1 *0 "y trolley + + + "y trolley +

%an type flow process chart Eob polishing the Specimen for metallographic study

*7 meters %etallographic lab

. / /

Start polishing the machine Sprinkle the solution of polishing compound on the rotating table Hold the Specimen in hand 4lace the Specimen gently on the rotating table $ polish it Wait for few seconds

- meters
0 2 3 1

Wash the Specimen ;ach the specimen Wash the Specimen again =ry it.

<heck under microscope Feep specimen in container

T.o Ha)/e/ Process Chart

*. Ased when an operator is using both hands for doing an activity. -. !he activities of both hands can be synchronized by providing a time scale on the chart. .. &nce the activities have been recorded, they are e,amined with a view to eliminate wasteful, unnecessary, uneconomical and non essential materials. 2emaining motions are simplified and re+sequenced to achieve better performance $ operator comfort. /. <hart is used for analysing repetitive 'obs of short duration $ assembly work.

0o" Asse!"# o% N(t 1 +o#t >eft Hand 4ick Ap Hand Hold Hold Hold

T.o Ha)/e/ Process Chart Symbols 2ight Hand I=>; 4ick up net !o >eft Hand :ssemble ?Screw Ap@

WORK MEASUREMENT
Work measurement technique finds the time require to complete the 'ob buy a qualified operator working at a standard pace $ using the standard method.

!he time ?in minutes or hours@ thus calculated is known as standard time. !he method to do the 'ob is normally standardized by using method study?motion study@ procedures before carrying out work measurement or time study. !he commonly employed work techniques are)+ *. Stop watch -. 4re+determined motion time system ?4%!S@ .. Work sampling or activity sampling technique Steps involved for work measurement ?!ime study@ *. Select the work to be studied $ determine the ob'ective of study -. &btain the improve procedure for doing the 'ob from the method study department .. Select the work for study /. !ake the worker as well as the shop supervisor into confidence $ e,plain to them the ob'ective of the study 0. <ollect the equipment include 'igs $ fi,tures for time study $ check their accuracy 1. ;,plain to the worker the improved working procedure $ the use of tools , 'igs $ fi,tures etc. 3. "reak the 'ob into operations $ operations into elements $ write them on the paper 5. =etermine the number of observations to be levied for each element 6. <onduct the observation?of tuning the elements @ and record items on time study form *7.2ate the performance of the worker during step 6 above **.2epeat steps 6 $ *7 for taking more than one observation *-.<ompute observed time *..<alculate normal time from observed time by using performance rating factor */.:dd process allowance, rest $ persona allowance $ special allowances to normal time to obtain S!:G=:2= !I%; ?or allotted time@ Process a##o.a)ce is meant to compensate workers for enforced idleness due to the nature of a process or an operation.

STANDARD TIME

It may be defined as the amount of time required to complete a unit of work ?:@ under e,isting working conditions ?"@ Asing the specified method $ machinery, ?<@ by an operator able to do the work in a proper manner $ ?=@ at a standard place. "asic time ( normal time It is the time required to perform a task by a normal operator working at a standard pace with no allowance for personal delays, unavoidable delays or fatigue. "asic time ( normal time H observed time I observed rating of operator standard rating i.e.*77 S!&4 W:!<H *. Gon fly "ack ?normal stop watch@ &ne press of knob+ starts. !wo press of knob+ stops. !hree press of knob+ comes to zero. our press of knob+ starts again.

-.

ly "ack+ or timing two observations one after other fly back stop watch is used. &ne press of knob+ starts. 4ress slide+ stops. -nd 4ress of knob+ hand comes to zero and starts automatically.

PREDETERMINED MOTION TIME SYSTEM ,PMTS!his technique does not measure element time by a stop watch $ thus avoids inaccuracies of time measurement. It is assumed that all the manual task in industries are made up off certain basic human movements ?like reach, move, engage etc.@ which are common to almost all 'obs. &nce the 'ob is broken down into its elements, the predetermined timings?available on records@ for each of these elements are added $ the normal time is obtained. Standard time may be obtained by adding proper allowances)+ &bserved time ?by actual time study or measurement by stop watch@ Gormal time H observed time I performance rating *77

Standard time H normal time J allowances ?process J rest J personal allowance@

WORK SAMP*ING =efinition )+ work sampling or activity sampling ?or ration delay study@ is a work measurement technique in which a large number of instant observations are made at random intervals over a specified time of one or group of machines, process or workers. ;ach observation records what is happening at that instant $ the percent of observations recorded for a particular activity or delay is a measure of percentage of time during which the activity or delay occurs. !his technique is based on statistical theory of sampling $ probability theory. #ood technique takes much less time $ accuracy is J -K. S!;4S IGC&>C;= *. =efine the problem -. %ake sure all persons connected with the study understand the ob'ectives of the study .. =ecide the number of observations to be made for a particular percentage accuracy ?say -077@ /. =ecide the time over which observations are to be made ?say *77 hrs@ 0. >ay down the random frequency over which these observations would be made e.g. 5.77, 5.*0, 5..7, 6.77 L L L ?from say 5 am to . pm everyday@ 1. &bserve the number of articles produced during these period ?say 1777@ 3. 2ecord the number of times the work was going on ?say -*77 times@ proportion of working time H -*77 I *77 H 5/K -077 time taken to make one article H 5/ I *77?study time @ ( 1777 ?units@ *77 &2 H 5/ I *77 I 17 minutes H 7.5/ minutes *77 1777

If the ration between manual time $ machine was - ) * then

%anual labour time H - I 7.5/ H 7.01 mts . %achine labour time H 7.-5 mts therefore normal time H 7.01 I rating ?say *.*0@ J 7.-5 machine time H 7.01 I *.*0 J 7.-5 H .6-/ minutes Standard time H .6-/ J allowances say 7.*- mts H .*H *.7// mts <omparison of work sampling $ time study W&2F S:%4>IG# Simple $ less costly Study may be interrupted in between Go stop watch required !I%; S!A=D by stop watch method %ore e,pensive It should not be interrupted Stop watch required