production management work study....

1. WORK STUDY

2. Meaning:-
 Work study or work analysis is the discipline of industrial
engineering that uses various techniques to quantitatively
measure or estimate work to increase the amount produced from
a given quantity of resources by improving the use of existing
resources.

3. Definition :-
 Work study is defined as that body of knowledge
concerned with the analysis of the work methods and the
equipment used in performing a job, the design of an
optimum work method and the standardization of proposed
work methods.
 Work study is also understood as a systematic objective
and critical examination of the factors affecting productivity
for the purpose of improvement. It make use of techniques
of method study and work measurement to ensure
the best possible use of human and material resources in
carrying out specific activity.

4. WORK
ANALYS
IS
Method Study
Work
Measurement
Enhance
Productivity
To simplify the job
Develop better
methods
Quantitatively
measure work

5. DEFINITIONS:-
• Method study:- the systematic recording and critical
examination of existing and proposed ways of doing work as a
means of developing and applying easier and more effective
methods and reducing costs.
• Work measurement:-the application of techniques ,deigned to
establish the time for a qualified worker, to carry out a specified
job at a defined level of performance.

6. Objectives of Work Study
• To analyze the present method of doing a job , systematically in
order to develop a new and better method
• To measure the work content of a job by measuring the time
required to do the job for a qualified worker and hence to
establish standard time.
• To increase the productivity by ensuring the best possible use of
human, machine and material resources and to achieve best
quality product/service at minimum possible cost.
• To improve operational efficiency.

7. WORK
DESIGN
Method
study/Operation
Analysis
Work
Measurement
Motion Study
Time Study
Developed by Gilberts Developed by Taylor
Objective:-
Improve
operations by more
effective
utilization of all
resources
Objective:-Improve
control by more
accurate planning,
manning estimating
and evaluating
performance.
Relationship of Time and Motion Study to Work
study
(Used to evaluate alternate
design/methods)
(Used to find the fastest motion
sequence)

8. Basic work study Procedure
 Select the job or the process or the operation to be studied
 Record all relevant facts about the job or process or operation
using suitable charting techniques such as operation process
charts, flow process charts etc..
 Examine critically all the recorded facts ,questioning the purpose
place,sequence,person and the means of doing the
job/process/operation.

9. Basic work study Procedure
• Develop the new method for the job/process/operation
• Measure the work content and establish the standard time using
an appropriate work measurement technique
• Define the new method for the job/process/operation
• Install the new method as standard practice.
• Maintain the new method for the job/process/operation

10. Benefits of Work Study
 Increased productivity and operational efficiency.
 Reduced material cost.
 Improved work place layout.
 Better manpower planning and capacity planning.
 Fair wages to employees.
 Better working conditions to employees.
 Improved workflow.

11. Method Study Work Study Work
Measurement
Select the work to be studied
Record the present method to limit of detail
economically justified using
Operation
process chart
Flow Process
Charts Motion
Charts
Film Analysis
charts
Examine the facts critically considering in turn purpose
place ,sequence ,person and means.
Develop best method under prevailing
circumstances
Define new methods
Install and maintain the new method to
achieve
Higher
Productivity
Select the work to be Measured
Record where necessary effective and in
effective time under existing working
condition.
Examine in order to eliminate
ineffective time.
Define method to be used
Breakdown job into elements
Measure quantity of work involved in
the method by
Time study Synthesis
Analytical
estimating
Estimate normal time and add relevant
allowances to determine standard time
or work unit value
To achieve

12. Method study
 Work methods analysis or methods study is a scientific
technique of observing, recording and critically examining the
present method of performing a task or job operation with the
aim of improving the present method and developing a new and
cheaper method.

13. Objectives of methods study
 To study the existing / proposed method of doing any job or activity.
 To develop an improved method to improve productivity and to
reduce operating cost.
 To reduce excessive material handling movement and thereby reduce
fatigue of workmen.
 To improve utilization of workers.
 To eliminate wasteful and inefficient motions.
 To standardize work methods or processess,working
conditions,machinery,equipment and tools.

14. Advantages of Method study
 Work simplification
 Improved working methods
 Better product quality
 Improved workplace layout
 Improved equipment design
 Better working conditions
 Better material handling and lesser material handling cost
 Improved work flow
 Less fatigue to operator
 Optimum utilization of all resources
 Higher safety to work men
 Shorter production cycle time
 Higher job satisfaction of workmen
 Reduce material consumption and wastage
 Reduced manufacturing cost and higher productivity.

15. Factors facilitating Methods Study
 High operating cost
 High wastage and scarp
 Excessive movement of material and workmen
 Excessive production bottlenecks
 Complaints about quality
 Complaints about poor working conditions
 Increasing number of accidents
 Excessive use of overtime

16. Method Study Procedure
1. Select the work or job to be studied and define objectives to be
achieved by method study.
2. Record all relevant facts or information pertaining to the existing
method using the recording techniques such as
Process Charts: Outline process chart
Operation process chart
Flow process chart
Man-Machine chart
Multiple activity chart
Simultaneous motion chart
Motion chart
Film analysis chart

17. Process Charts
 The different kinds of process chart share a common core set of
symbols, though some have additional symbols for specific and
specialized process steps.
 The common symbols (of which there are only five) were first
promulgated by the American Society of Mechanical Engineers
and have become known as the ASME symbols.

18. OPERATION: a main step, where the part, material
or product is usually modified or changed
INSPECTION: indicates a check for quality or
quantity
TRANSPORT: the movement of workers, materials
or equipment
STORAGE: controlled storage in which material is
received into or issued from a store, or an item is
retained for reference purposes
DELAY or TEMPORARY STORAGE: indicates a
delay in the process, or an object laid aside until
required.
Combined activity

19. Operation Process Chart
 A graphic representation that gives an overall view of an entire
process, including the points at which materials are introduced,
the sequence of inspections, and all operations not involved in
material handling.

21. Flow Process Chart
 The Flow Process Chart records the steps in a process along a
vertical line, with the action type being shown by a symbol
alongside a description of the action, as in the illustration

24. Man-Machine chart
 Man-machine chart is a chart relation of how much time the machine
spend while the man or the operator spending his time on his job.
 The man-machine chart, or simochart, is a planning industrial
graphically defining resources' activity (robots, operators, ...) at
repetitive tasks. It is typically used to plan the activity of resources in
large and medium series.
 Each resource continually performs the same tasks. When the last task
is completed, the resource runs again the first task. This estate is
called cycle.
 A diagram is constituted of tangled cycles. The duration of the
longest cycle is called time of cycle. It is usually the time needed to
produce or assemble a piece.

27. Multiple activity charts
 Multiple activity charts are used to show the interrelationships
of individuals in teams of workers, or the relationships between
workers and equipment, usually during the record stage of
method study.
 The activities of each subject (whether worker or equipment) are
recorded, normally as blocks in columnar form, against a
common time scale.

29. Diagrams such as
Flow diagram
String diagram
Cycle graph
chronocyclegraph
 Examine the recorded facts critically by asking questions like
What is done?What is the purpose of the operation?Why should
it be done? who does the work?Why is it done there?When is the
work done? How is the work done?

30. Flow diagram
 A flow diagram is a graphical means of presenting, describing, or
analyzing a process. This is done by drawing small boxes which
represent steps or decisions in a chain of steps or decisions.

31. Flow diagram

32. String Diagram
 The String Diagram is a simple tool for analyzing and designing
work spaces such that movement can be minimized. The basic
diagram simply consists of a map of the work area, with the
actual movements drawn on top.

34. Method Study Procedure
3.Examine the above facts critically:-Critical examination is done
by questioning technique. This step comes after the method is
recorded by suitable charts and diagrams.
The individual activity is examined by putting a number of
questions. The following factors are questioned
 Purpose – To eliminate the activity, if possible.
 Place – To combine or re-arrange the activities.
 Sequence – -do-
 Person – -do-
 Means – To simplify the activity.

35. The following sequence of questions is used:
 Purpose – What is actually done?
Why is it done?
What else could be done?
What should be done?
 Place – Where is it being done?
Why is it done there?
Where else could it be done?
Where should it be done?

36.  Sequence – When is it done?
Why is it done then?
When could it be done?
When should it be done?
 Person – Who is doing it?
Why does that person do it?
Who else could do it?
Who should do it?
 Means – How is it done?
Why is it done that way?
How else could it be done?
How should it be done?

37. By doing this questioning
 Unwanted activities can be eliminated
 Number of activities can be combined or re-arranged
 Method can be simplified.
All these will reduce production time.

38. Method Study Procedure
4.Develop the improved method by generating several alternatives and
selecting the best method.
The answer to the questions given below will result in the
development of a better method.
 Purpose – What should be done?
 Place – Where should it be done?
 Sequence – When should it be done?
 Person – Who should do it?
 Means – How should it be done?

39. The factors to be considered while evaluating
alternatives and selecting the best method are:
1. Cost of implementation
2. Expected savings in time and cost
3. Feasibility
4. Producibility
5. Acceptance to design, production planning and control, quality
control, production and sales departments
6. Reaction of the employees to new method
7. Short term or long term implication of alternatives

40. Method Study Procedure
5. Define
Once a complete study of a job has been made and a new
method is developed, it is necessary to obtain the approval of the
management before installing it. The work study man should
prepare a report giving details of the existing and proposed
methods. He should give his reasons for the changes suggested.

41. The report should show
(a) Brief description of the old method.
(b) Brief description of the new method.
(c) Reasons for change.
(d) Advantages and limitations of the new method.
(e) Savings expected in material, labour and overheads.
(f) Tools and equipment required for the new method.
(g) The cost of installing the new method including.
1. Cost of new tools and equipment.
2. Cost of re-layout of the shop.
3. Cost of training the workers in the new method.
4. Cost of improving the working conditions.

42. Written standard practice:
Before installing the new method, an operator‘s instructions sheet
called written standard practice is prepared. It serves the
following purposes:
 It records the improved method for future reference in as much
detail as may be necessary.
 It is used to explain the new method to the management
foreman and operators.
 It gives the details of changes required in the layout of machine
and work places.
 It is used as an aid to training or retraining operators.
 It forms the basis for time studies.

43. Written standard practice:
The written standard practice will contain the following
information:
(a) Tools and equipment to be used in the new method.
(b) General operating conditions.
(c) Description of the new method in detail.
(d) Diagram of the workplace layout and sketches of special tools,
jigs or fixtures required.

44. Method Study Procedure
6.Install the improved method in three phases- planning, arranging
and implementation phases.
This step is the most difficult stage in method study. Here
the active support of both management and trade union is
required. Here the work study man requires skill in getting along
with other people and winning their trust.

45. Install stage consists of
(a) Gaining acceptance of the change by supervisor.
(b) Getting approval of management.
(c) Gaining the acceptance of change by workers and trade unions.
(d) Giving training to operators in the new method.
(e) To be in close contact with the progress of the job until it is
satisfactorily executed.

46. Method Study Procedure
 7. Maintain the new method by ensuring that the installed
method is functioning well.
The work study man must see that the new method
introduced is followed. The workers after some time may slip
back to the old methods. This should not be allowed. The new
method may have defects. There may be difficulties also. This
should be rectified in time by the work study man.
Periodical review is made. The reactions and suggestions from
workers and supervisors are noted. This may lead to further
improvement.
The differences between the new written standard practice and
the actual practice are found out. Reasons for variations are
Analysed. Changes due to valid reasons are accepted. The
instructions are suitably modified.