10 work measurement

8/8/2019 10 Work Measurement

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ModuleModule --1010ModuleModule --1010

Productivity & Work MeasurementProductivity & Work Measurement


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OverviewOverviewOverviewOverview

Work Measurement /Work Measurement /

Time StudyTime Study

Motion StudyMotion Study

PMTS techniques of workPMTS techniques of work

measurementmeasurement


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WORK STUDYWORK STUDYWORK STUDYWORK STUDY Concerns with better ways of doingConcerns with better ways of doing

things and control over output of thosethings and control over output of those

things by setting standards with respect tothings by setting standards with respect to

time.time. Components of Work StudyComponents of Work Study ::

(a)(a) Method StudyMethod Study : Means of improving: Means of improving

ways of doing things,ways of doing things,

(b)(b) Time studyTime study (Work measurement)(Work measurement)


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WORKMEASUREMENTWORKMEASUREMENTWORKMEASUREMENTWORKMEASUREMENT

TIME STUDYTIME STUDY


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USES OF TIME STUDYUSES OF TIME STUDYUSES OF TIME STUDYUSES OF TIME STUDY

To determine the work contentsTo determine the work contentsand thereby setting wages andand thereby setting wages and

incentives.incentives. To arrive at cost standards perTo arrive at cost standards per

unit of output,unit of output,

To compare work efficiency ofTo compare work efficiency of

different operationsdifferent operations,, more..more..


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USES OF TIMEUSES OF TIME STUDYSTUDY (CONT.)(CONT.)USES OF TIMEUSES OF TIME STUDYSTUDY (CONT.)(CONT.)

ToTo arrive at job schedules,arrive at job schedules,

Manpower planning,Manpower planning,

To aid in method studyTo aid in method study

Product design by providingProduct design by providing

basic data onbasic data on costs ofcosts ofalternative materials andalternative materials and

methods.methods.


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BASIC SYSTEMS OF TIME STUDYBASIC SYSTEMS OF TIME STUDYBASIC SYSTEMS OF TIME STUDYBASIC SYSTEMS OF TIME STUDY

Time standardTime standard is establishedis establishedthrough the following threethrough the following three

methods :methods : Stopwatch studyStopwatch study

Predetermined motion timePredetermined motion timesystems (PMTS)systems (PMTS)

Work SamplingWork Sampling


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Steps of Work Methods AnalysisSteps of Work Methods AnalysisSteps of Work Methods AnalysisSteps of Work Methods Analysis

1.1. Make an initial investigation of theMake an initial investigation of theoperation under considerationoperation under consideration

2.2. Decide what level of analysis isDecide what level of analysis is

appropriateappropriate3.3. Get suggestions from anyone familiarGet suggestions from anyone familiar

with operationwith operation

4.4. Thoroughly describe and evaluate presentThoroughly describe and evaluate presentmethodmethod

5.5. Devise a new proposed methodDevise a new proposed method


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Steps of Work Methods AnalysisSteps of Work Methods AnalysisSteps of Work Methods AnalysisSteps of Work Methods Analysis

66.. Compare new and present methodsCompare new and present methods

7.7. Modify the proposed methodModify the proposed method

8.8. Perform the proposed method on aPerform the proposed method on atrialtrial basisbasis

9.9. Install the proposed method andInstall the proposed method and

train workerstrain workers

10.10. Check on new method periodicallyCheck on new method periodically


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Work MeasurementWork MeasurementWork MeasurementWork Measurement

Work measurementWork measurement refers to therefers to the

process of estimating the amount ofprocess of estimating the amount of

worker time required to produce oneworker time required to produce oneunit of output.unit of output.

A goal of work measurementA goal of work measurement is tois to

develop labor standards that can bedevelop labor standards that can beused for planning and controllingused for planning and controlling

operations.operations.


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Labor StandardsLabor StandardsLabor StandardsLabor Standards

AA labor standardlabor standard is the number ofis the number ofworkerworker--minutes required to complete anminutes required to complete an

element, operation, or product underelement, operation, or product under

ordinary operating conditions.ordinary operating conditions.

Ordinary operating conditionsOrdinary operating conditions

refers to a hypothetical average situation,refers to a hypothetical average situation,average or typical worker, material,average or typical worker, material,

machinery, environment, etc.machinery, environment, etc.


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Labor standards are used in:Labor standards are used in:

Cost estimationCost estimation

Pricing of products and servicesPricing of products and services

Incentive pay systemsIncentive pay systems

Capacity planningCapacity planning Production schedulingProduction scheduling


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A labor standard can be determined usingA labor standard can be determined using

one or more of the following approaches:one or more of the following approaches:

Time studyTime study

Work samplingWork sampling

Predetermined time standards (subjective)Predetermined time standards (subjective)

Historical standardsHistorical standards Supervisor estimatesSupervisor estimates


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TIME STUDYTIME STUDY

Carried out to get the standardCarried out to get the standardtimes for the work to arrivetimes for the work to arrive

at labor standardat labor standard


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Time StudyTime StudyTime StudyTime StudySuitable JobsSuitable Jobs for Time Study :for Time Study : Job performed by a single worker in aJob performed by a single worker in a

fixed locationfixed location

Job involves repetitive short cyclesJob involves repetitive short cycles

Job expected to continue unchanged for aJob expected to continue unchanged for a

long periodlong period

Job produces large quantities of outputJob produces large quantities of output

Where resultingWhere resulting time standard must betime standard must be

veryvery accurate,accurate, more..more..


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Time StudyTime StudyTime StudyTime Study Analysts useAnalysts use stopwatchesstopwatches to time theto time the

operation being performed byoperation being performed by

workersworkers

These observed times are thenThese observed times are then

converted intoconverted into labor standardslabor standards

The labor standards are expressed inThe labor standards are expressed inminutes per unitminutes per unit of output for theof output for the

operationoperation


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Determining Labor StandardsDetermining Labor Standards

from Time Studiesfrom Time Studies



ObservedObserved

TimeTime

NormalNormal

TimeTime

StandardStandard

TimeTime

PerformancePerformance

RatingRating

AllowanceAllowance

FractionFraction


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1.1. Make sureMake sure correct methodscorrect methods are being used toare being used to

perform the operation being studied.perform the operation being studied.

2.2. Break the operation down into basic tasksBreak the operation down into basic tasks

((elementselements).).

3.3. Determine how many cycles to time. ADetermine how many cycles to time. Acyclecycle

is one complete set of the elemental tasks.is one complete set of the elemental tasks.

4.4. Observe and record the elapsed time for eachObserve and record the elapsed time for eachelement for the number of required cycles.element for the number of required cycles.

. . . more. . . more


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from Time Studies (contd.)from Time Studies (contd.)


from Time Studies (contd.)from Time Studies (contd.)

5.5. For each element, estimate the observedFor each element, estimate the observedworkersworkers performance ratperformance ratinging. A rating. A ratingof 1.00 indicates the worker is working atof 1.00 indicates the worker is working at

normal speed.normal speed.6.6. Compute the allowance fraction for theCompute the allowance fraction for the

operation. Theoperation. The allowance fractionallowance fraction isis

the fraction of time that workers cannotthe fraction of time that workers cannotwork through no fault of their own.work through no fault of their own.



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7.7. Compute theCompute the mean observed timemean observed time for eachfor eachelementelement::

(Sum of observed element times)(Sum of observed element times)

(Number of cycles timed)(Number of cycles timed)

8.8. Compute theCompute the normalnormal timetime for each elementfor each element::

= (Mean observed time)= (Mean observed time) xx (Performance(Performance rating)rating)


==


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9.9. Compute theCompute the total normal timetotal normal time for thefor theentire operation:entire operation:

= (Sum of element normal times for all= (Sum of element normal times for all

elements)elements)

10.10. Compute theCompute the labor standardlabor standard for thefor the

operation:operation:

= (Total normal time)= (Total normal time) // (1(1 -- AllowanceAllowancefraction)fraction)


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Example: Time Study ApproachExample: Time Study ApproachExample: Time Study ApproachExample: Time Study Approach

In aIn a time studytime study of a manufacturingof a manufacturing

operation, the average time observed tooperation, the average time observed to

complete a product was 8.6 minutes. Thecomplete a product was 8.6 minutes. The

performance rating applied to theperformance rating applied to the

observed worker was 0.95 and theobserved worker was 0.95 and the

allowance during an 8allowance during an 8--hour shift washour shift was

12.5% or60 minutes.12.5% or60 minutes.

Compute the labor standard.Compute the labor standard.


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Example: Time Study ApproachExample: Time Study ApproachExample: Time Study ApproachExample: Time Study Approach

Observed timeObserved time =8.6 minutes=8.6 minutes Performance ratingPerformance rating = 0.95= 0.95

Allowance fractionAllowance fraction = 0.125= 0.125

Normal time = Observed timeNormal time = Observed time xx Performance ratingPerformance rating

=8.6=8.6xx 0.950.95

=8.17 minutes=8.17 minutes

Standard Time =Normal time / (1Standard Time =Normal time / (1 -- Allowance)Allowance)

=8

.17

/ (1=8

.17

/ (1 -- .125).125)

=8.17 / (0.875)=8.17 / (0.875)

= 9.337 minutes= 9.337 minutes


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TIME STUDYTIME STUDY WORKERS FEELINGSWORKERS FEELINGSTIME STUDYTIME STUDY WORKERS FEELINGSWORKERS FEELINGS

WorkersWorkers do not like to be controlled fromdo not like to be controlled from

outside force through labor standards andoutside force through labor standards and

production quotasproduction quotas

Operations ManagerOperations Managerto apprise workers on allto apprise workers on allpersonnel being in same situationpersonnel being in same situation

ProblemsProblems to be solved jointly by managers andto be solved jointly by managers and

workers for economic health of companyworkers for economic health of company Teamwork conceptTeamwork concept will help overcome badwill help overcome bad

feelings towards labor standardfeelings towards labor standard


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WORKSAMPLINGWORKSAMPLINGWORKSAMPLINGWORKSAMPLING

AnotherAnother

work measuringwork measuringtechnique that helps intechnique that helps in

arriving at labor standardarriving at labor standard


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Work SamplingWork SamplingWork SamplingWork Sampling

The work of one or more employees isThe work of one or more employees is

randomly sampled at periodic intervalsrandomly sampled at periodic intervals

TheThe proportion of the total operation thatproportion of the total operation that

is accounted for in one particularis accounted for in one particular activityactivity

is notedis noted

The results of these studies are used to:The results of these studies are used to: Set allowances used in labor standardsSet allowances used in labor standards

Set labor standardsSet labor standards


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Work SamplingWork SamplingWork SamplingWork Sampling

Suitable Jobs :Suitable Jobs : Job performed by a single worker in a fixedJob performed by a single worker in a fixed

locationlocation

Job involves repetitive short cyclesJob involves repetitive short cycles Job expected to be changed periodically asJob expected to be changed periodically as

customer orders changecustomer orders change

Job produces relatively small quantities of outputJob produces relatively small quantities of output Where resultingWhere resulting time standardtime standard are usedare used forfor

accounting cost standard, pricing analysis, andaccounting cost standard, pricing analysis, and

production planninproduction planningg


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Example: Work SamplingExample: Work SamplingExample: Work SamplingExample: Work Sampling

A work sampling study was performed on anA work sampling study was performed on anelectronic assembly operation at OK Instruments.electronic assembly operation at OK Instruments.The study covered an 8The study covered an 8--hour shift with a singlehour shift with a singleworker. The results of the study were:worker. The results of the study were:

ActivityActivity % of Workers Time% of Workers Time

Assemble UnitsAssemble Units 8080

AllowancesAllowances 2020

If the worker received a performance rating ofIf the worker received a performance rating of1.20 on the Assemble Units activity and 400 units1.20 on the Assemble Units activity and 400 unitswere assembled during the study, what is the laborwere assembled during the study, what is the laborstandard for this operation?standard for this operation?


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Example: Work SamplingExample: Work SamplingExample: Work SamplingExample: Work Sampling

1) Compute the1) Compute the average time peraverage time per assembly:assembly:== (Total(Total Minutes ofAssemblyMinutes ofAssembly Work) /Work) /

(Number(Number of Unitsof Units Assembled)Assembled)

= .8(480)/400 = .960 minutes per unit= .8(480)/400 = .960 minutes per unit

22) Compute the) Compute the normal time per unit:normal time per unit:

= (Average Time per Unit)(Performance Rating)= (Average Time per Unit)(Performance Rating)

= .960(1.20) = 1.152 minutes per unit= .960(1.20) = 1.152 minutes per unit

3) Computethelabor standard:= NormalTime/(1 AllowanceFraction)

= 1.152/(1 - .20) = 1.44 minutesperunit


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PREDETERMINEDPREDETERMINEDMOTION TIME SYSTEMSMOTION TIME SYSTEMS

(PMTS)(PMTS)

Another approach toAnother approach to

determination of labordetermination of laborstandardsstandards


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Predetermined Time StandardsPredetermined Time StandardsPredetermined Time StandardsPredetermined Time Standards

Method ofMethod ofwork measurementwork measurement commonlycommonly used forused fornew operations or new productsnew operations or new products

When labor standard must be determined in advanceWhen labor standard must be determined in advanceof performing an operationof performing an operation

Utilize data that have been historically developed forUtilize data that have been historically developed forbasic body movements, elements of operations, andbasic body movements, elements of operations, andentire operationsentire operations

Many predetermined time standard systems are used:Many predetermined time standard systems are used: Work factorWork factor MethodsMethods--time measurement (time measurement (MTMMTM)) Basic motion time (Basic motion time (BMTBMT) study) study and others custom designed for companiesand others custom designed for companies


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Suitable JobsSuitable Jobs

Job performed by many workers over a compact areaJob performed by many workers over a compact area

Tasks may involve little repetition, but if repetitiousTasks may involve little repetition, but if repetitious

the cycles are very longthe cycles are very long Workers must be observed by a single analystWorkers must be observed by a single analyst

A moderate degree of accuracy in the labor standardA moderate degree of accuracy in the labor standard

is desirable, but a time study is too costlyis desirable, but a time study is too costly

Only large elements of work need to be observedOnly large elements of work need to be observed

Little detail is needed in setting the timeLittle detail is needed in setting the time standardstandard

moremore


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SuitableSuitable Jobs (contd.)Jobs (contd.)

Any job or group of jobs in which:Any job or group of jobs in which:

Very accurate labor standards are notVery accurate labor standards are notrequired, orrequired, or

The cost of time study, predeterminedThe cost of time study, predetermined

time standards, and work sampling istime standards, and work sampling isprohibitiveprohibitive


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METHODS TIME MEASUREMENT (METHODS TIME MEASUREMENT (MTMMTM))METHODS TIME MEASUREMENT (METHODS TIME MEASUREMENT (MTMMTM))

The basicThe basic MTMMTM approach to PMTS is :approach to PMTS is : to classify the human work motions into certainto classify the human work motions into certain

fixed categories such as reach, move, turn, applyfixed categories such as reach, move, turn, apply

pressure, grasp, release, position, eye motions,pressure, grasp, release, position, eye motions,

bodybody--legleg--andand--foot motions etc,foot motions etc,

time them,time them,

and create anand create an inventory of standard microinventory of standard micro--motionsmotions

A job is visualized to consists of a series of microA job is visualized to consists of a series of micro--

motions frommotions from MTMMTM inventory of standard microinventory of standard micro--

motionsmotions


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End ofEnd of ModuleModule--1010End ofEnd of ModuleModule--1010

10 work measurement

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