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Work StudyWork Study

30th October, 2007

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What is work StudyWhat is work Study

Work Study is defined as process which is used

to examine human work in all its contexts.

It leads to systematic investigations of all

factors which effect the efficiency of situation

being reviewed

To Seek

Improvements

It aims at finding the best and efficient way of

using :

Men , Material, Money & Machinery

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Elements of Work StudyElements of Work Study

Method and Motion Study:

Work Measurement

Systematic investigation of existing method in order to

develop and install an easy ,rapid ,efficient , effective and

less fatiguing procedure for doing same job at lower

costs.

Done by eliminating unnecessary motions, alteration of

sequence in a process or alteration of process itself

Application of different techniques to measure and

establish the time required to complete the job by a

qualified worker at a defined level of performance

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Work Study – Advantages & ApplicationsWork Study – Advantages & Applications

Advantages: Unfiform and improved production flow

Higher productive efficiency

Reduced manufacturing costs

Fast and accurate delivery dates

Better Wage setting procedures

Applications of Work Study: Industries ( production operations,research and development)

Marketing,sales and distribution

Offices,stores and warehouses,

Material handling

Building and constructions

Hospitals and army and agriculture.

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Method Study - Procedure Method Study - Procedure Select and set objectives:

To reduce manufacturing cost

Reduce bottle neck

Increase operator efficiency

Record all data pertaining to existing method by: Process Charts :

1. Flow process chart

2. Two handed process chart

3. Multiple activity chart

Flow Diagrams

Models

Motion and film analysis:

1. Simo chart - Simultaneous Motion Chart

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Flow Process Charts for Data Recording Flow Process Charts for Data Recording This chart uses

circles for operationsarrows for transportssquares for inspections triangles for storageletter D for delays.

Sl. No.

Operation Machine

1 StorageIn

trolley

2 Coining Press

3 Bearing Pressing Press

4 Ball Pressing Press

5Leak Check& Poppet Assy.

Table

6Thrust washer

Assy.Poka-Yoke

1 5 0 0 0

After Layout Revision Process

Total

Sl.No

.

Operation Machine

1 StorageFrom In trolley

2 Coining Press

3Storage + Relief

Plug Assy.Trolley

4 Ball Pressing Press

5 StorageOn the

Machine

6 Leak Check Air Gauge

7 Storage Table

8Poppet

assemblyTable

9Bearing Pressing

Press

10 Storage Table

11Thrust washer

Assy.Poka-Yoke

12 Storage --

6 6 0 1 4

Before Layout Revision Process

Total

This chart is of 3 types:

Man – Activities of operator

machine - Manner in which the equipment is used

Material - the changes the material undergoes in location or condition

Vertical lines connect these symbols in the sequence they are performed.

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Two handed process chart records the activities of left and

right hand as related to each other

Two handed Process Charts for Data Recording Two handed Process Charts for Data Recording

• Use of human body

• The two hands should begin and complete their movements at the same time

• The two hands should not be idle at the same time except during periods of rest

• Motions of the arms should be symmetrical,in opposite direction and simultaneous

• Continuous curved movements are to preferred to straight line motions involving sudden and sharp,changes in direction

• Work should be arranged so that eye movements are confined to a comfortable area, without the need for frequent changes of focus

Activity LH RH

Operation 1 2

Transport 0 1

Check ing 0 0

Storage 3 1

Summary of Saving

Left hand Operation LH RH

Pick up Bolt

Hold

Hold

Hold

Right hand Operation

Process

Idle

Pick up Nut

to left hand

assemble

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Multiple Activity Charts for Data Recording Multiple Activity Charts for Data Recording

This chart records simultaneously the activities of all the workers and machine on a

common time scale and shows inter- relations between them

To detect idle times and to decide no. of workers

To balance work team and optimize work distributions between workers

Applications:

Plant repair and

maintenance

Planning team work

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Flow Diagram depicts the probable

movement of materials in the floor plant.

The movement is represented by a line

in the plant drawing.

Flow Diagram for Data Recording Flow Diagram for Data Recording

This chart indicates the movement of

men and materials

If these movement are reduced it will

lead to cost and effort reduction

The path of movements can be

better visualized

Measures the distances moved and

points out if the work stations are

suitably located

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Method Study - Procedure Method Study - Procedure Examine – asking questions

Purpose – what is done ?

Person – Who does it ?

Place – Where it is done ?

Means – how is it done ?

Sequence – When it is done

1. Why is it necessary ,why is it done by that method etc.,

2. Determine alternate ways of doing

3. Determine best method of of doing

Operation Analysis

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Method Study - Operation AnalysisMethod Study - Operation Analysis Detailed study of different operations involved In doing a work

Some of the work elements to be

Combined

Eliminated

Altered in sequence

Operation analysis involves in optimizing the processes with regard to:

Worker in terms of fatigue

Setup in terms of modification of setup, availability of equipments and number of setups

Material specification,cost

Material handling – backtracking,distance reduction

Operations

Tools and fixtures – easy to use

Work condition – lighting,ventilation

Analysis of motion :

Identification of productive and idle motions

Elimination of unnecessary and non- productive motions

Redesign of the existing operatios by employing minimum number of motions and appropriate sequence

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Method Study - Work place Layout designMethod Study - Work place Layout design Materials and tools to be available in predetermined places closes to

the worler

To be located in the order of their use

Use of gravity , for raw material to reach operator wherever possible

Comfortable posture for operator

Should be able to operate levers and handles without alteration in body postures

Working place classification

Actual working area – most convenient area to work (1)

Normal working area – it is within the reach of the operator (2)

Maximum Working area - It is accessible with full arms stretch (3)

1 2

3

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Method Study - Procedure Method Study - Procedure

Develop best method which is :

Practical , feasible, safe and economical

Acceptable to design and production and quality control and

sales

Install developed method and examine for

problems

Maintain new method by periodic checks and

verifications

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Work measurement 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

Work MeasurementWork Measurement

A qualified worker is one who is:

Accepted as having the necessary physical attributes,

Who possesses the required intelligence and education,

Who has acquired the necessary skill and knowledge to carry out the work in hand to

Satisfactory standards of safety,quantity and quality

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Work Measurement - ApplicationWork Measurement - Application

The uses of work measurement

• To compare the efficiency of alternative methods

• To balance the work of members of teams, in association with Multiple activity chart

• To determine, in association with man machine multiple activity charts, the number of machines an operative can run

• The time standards, once set, may then be used:

– For production planning and scheduling

– Determine plant and Labour requirements

– To set standards of machine utilisation and Labour

performance and as a basis for incentive schemes

– To provide information for Labour-cost control

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Work Measurement Technique – Time StudyWork Measurement Technique – Time Study

Time study is a work measurement technique for recording the times and rates

of working for:

The elements of a specified job

Carried out under specified conditions,

Analysing the data so as to obtain the time necessary for carrying out the job

at a defined level of performance

Basic time study equipment

A stop watch

A study board

time study forms

camera

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Obtaining and recording all the information available about the job, the operative and the surrounding conditions

Recording a complete description of the method,breaking down the operation into elements

An element is a distinct part of a specified job selected for convenience of observation, measurement and analysis

A work cycle is the sequence of elements which are required to perform a job or yield a unit of production.The sequence may sometimes include occasional elements

Measuring with a timing device(usually a stopwatch) and recording the time taken for each element

At same time, assessing the effective speed of working(Rating)

Extending the observed times to Basic times

Determining the allowances to be made over and above the basic time for the operation

Determining the standard time for the operation

Time Study – Procedure Time Study – Procedure

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Rating

• Rating is the assessment of the worker’s rate of

working relative to the observer’s concept of the

rate corresponding to standard performance

How the rating factor is used

• Observed Time x Rating = Basic time

Standard Rating(100)

• Basic time is the time for carrying out an

element of work at standard rating

Time Study – Rating & Rating FactorTime Study – Rating & Rating Factor

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+ CA

Time Study – Standard TimeTime Study – Standard Time

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Work Measurement – Other TechniquesWork Measurement – Other Techniques

Predetermined Motion Time System (PMTS): Does not measure elemnt time

All manual tasks are made up of certain basic human movement which are common to all jobs

The average time taken to perform a movement is constant (BS 3138 :1969)

Basic time can be calculated by summing times of all motions and applying rating factor

Method Time Measurement (MTM): Time measurement unit ( 1 TMU = 0.0006 min.)

Analyses the human movements , depending on types of motion and conditions predetermined time values are given for each motion

Basic time can be calculated by summing times of all motions and applying rating factor