Improving the productivity and introducing the work study

contentsHow to improve work study?Reducing excess work contentReducing ineffective timeIntroduction to work studyTechniques of work studyBasic steps used in work study.

Improving the productivityHigher productivity of organization leads to

national prosperity and better standard of living.

This has motivated many organizations to improve productivity at different levels.

Importance of time and the difference between actual and required input for raising the productivity shall be focused in this presentation.

Productivity of a man/ machineTime required to do a job Basic work content Excess work content Ineffective

Increasing the productivity Reducing excess work content Reducing ineffective time

Tota

l ti

me t

o m

an

ufa

ctu

re u

nd

er

exi

stin

g c

on

dit

ion

s

Tota

l in

eff

ect

ive

tim

e

Tota

l w

ork

co

nte

nt

Basic work content of product/ production

Excess work content due to defect in design of product

Excess work content due to ineffective method of operation/

manufacture

ineffective time due to lack of management

ineffective time due to lack of workers

Reducing excess work content caused by imperfect designProduct development and value analysis.Design and production the people should work

together Improve the design in product development stage

itself(in light manufacturing and assembling needs)Alternation in design can be made for in reduced

material processing• Standardization and specializationTo reduce product variety increase batch size of productionAllows use of high volume production processes.

Reducing excess work content due to imperfect designProper quality standards

Market and consumer and research: needs of market and consumers.

Product research: technical requirement of product for longer and better performance.

Reducing excess work content due to inefficient manufacturingProcess planning function

Selection of machine for manufacturingNecessary tool are identified for useIdentification of processing parameters(speed,

feed etc)

Reducing excess work content due to inefficient manufacturingProcess planning and method study

Factory lay out (reducing unnecessary movements)

Developing improved working method

Method study and workers training For improved working method and so as to reduce

scrap

Reducing ineffective time due to management’s inefficiencyProductivity of an organization largely

depends on its production policy (batch size and expertise of worker)

Marketing policy of managementShould it go for specialized and standard

productShould it go for variety of products demanded

by each customer?Proper product development before

commencement of production: avoids redesign , wastage as scrap and rework.

Reducing ineffective time due to management’s inefficiencyProper production planning:

It makes job available to be done by the worker

It should be based on sound standards of production

These standards are set by work measurement.

Proper materials control Foresee the requirement of tools/raw materials Purchase them at economical prices Reduce inventory cost

Reducing ineffective time due to management’s inefficiencyProper maintenance results in

Tools and machines in good working conditionsReduced rejections and scrapGood working on environment and training of

workers on safety may lead to Reduce accidents absentees

Reducing ineffective time due to worker’s inefficiencySound personnel policy of management

Relationship between worker and managementTraining of workers and managers: worker/

attitude / carelessnessMotivational strategies (incentive, awareness,

vision, mission etc)Proper work/ rest schedule for workersProper working conditionsLooking into the grievances of worker and

demands

How to increase productivity?To increase productivity there may be many

methodsDevelopment of new manufacturing

methods/processesModernize the existing infrastructure and high

capacity machinesWork study

Comparison of methodsDevelopment of new manufacturing process/

methodsLong timeHuge investmentNo limit on increase in productivityModernize the existing infrastructure and high

capacity machinesPurchase of machines/ process technologyHuge investmentNo limit on increase in productivity Work study

Limited or no investment

EVOLUTION OF WORK STUDYF.W.TAYLOR: founder of modern method and

time study.Taylor began his time study work in 1881.He established that each job should have a

standard time, determined by time studies.In the timing process Taylor advocated

dividing the work into small divisions of effort known as elements.

Time was obtained for these element individually and their collective values were used to determine the allowed time for the task.

Work of GilbrethGilbreth is considered as the founder of

‘modern motion study technique’Which is defined as the study of body motions

used in performing an operation for the purpose of improving the operation by :

Eliminating unnecessary motionsSimplifying necessary motionsThen establishing the most favorable motion

sequence for maximum efficiency

Gilbreth’s workHe developed the technique of filming

motions for study, known as micro motion study.

The Gilbreth also developed the cycle graphic and chronocycle graphic analysis techniques for studying the motion paths made by an operator.

Consequently, with the chronocyclegraph it became possible to determine direction and compute velocity, acceleration and deceleration, in addition to study of body motions.

Work studyWork study may be defined as the analysis of

a job for the purpose of :-Finding the preferred method of doing it and Determine the standard time to perform it by

the preferred(or given) method.Work study therefore comprises of two areas

of study :Method study (motion study)Time study (work measurement)

What is work study?Work study is a generic term for those

techniques (method study and work measurement) which are used in examination of human work in all its contexts, and which lead to systematic investigation of all the factors affecting the efficiency and economy of a situation under review in order to effect improvement.

Linkage between work study and productivity is apparent from above.

Techniques of work studyMethod study: it is a technique of systematic

recording and critical examination of existing and proposed method of doing work for developing and applying easier and more effective method and reducing cost.

Work measurement: it is the application of techniques designed to establish the time for a qualified worker to carry out a specified job at a defined level of performance.

Method studyIt is mainly concerned with reduction of

added work content of a job.It is mainly used to improve the method of

doing work and develop an effective method for new jobs.

For existing jobs, method study aims to find better method which is economical and safe.Requires less human effortNeeds shorter make ready/ put away time.

Work measurementIt is mostly concerned with investigation and

reduction of any in effective time associated with existing job.

Subsequently establishment of time standard for the operation which has been improved my method study.

There is no hard and fast ‘whether improved study or work measurement is to be applied first.

It depends whether operation for a job has been perfected or not.

Relationship between work study techniques

Method studyTo simplify the job and

develop more economical methods of

doing a job

Work measurementTo determine how

long it should take it carry out

Work stud

y

Higher productivit

y

Effect of work studyApplication of work study technique in any

organization can result inGreater output at less costBetter qualityHigher productivity

Work study and ergonomics The work study and the ergonomics are the

two areas of having the same objective ‘ designing the work system so that operator is same , so that operator is safe,

Subjected to less fatigue Takes less time to do the job.

Basic steps of work studySelect: a job for studyRecord: direct observation or recording of

eventsExamine: critical study of recorded events to

check their needs.New/ improved method in light of prevailing

conditionsMeasure: quantity of work involved in

selected method to find standard time.Define: new/improved method