Time and Motion Study

4/11/2013
Copyright 2013 Anupam Kumar 1

Time & Motion Study
Presented By:
AnupamKumar
Reader
SMS Varanasi.
Email: anupamkr@gmail.com
1 Copyright 2013 Anupam Kumar
Time & Motion Study
Frederick W. Taylor and his followers developed and
refined the Time Study
A method created to determine the correct time it
takes to complete a certain task
Frank B. Gilbreth and his wife Lillian developed and
refined the Motion Study
A method to establish the one best way to perform a
task
Historically the two studies are discussed individually,
today they generally are discussed as one
Time Study
It is a work measurement technique
for recording the times and rates of working
for the elements of a specified jobs,
carried out under specific conditions
for analyzing the data
so as to obtain the time necessary
for carrying out the job
at an defined level of performance.
Motion Study
It is the science of eliminating wastefulness
resulting from using
unnecessary,
ill-directed and
inefficient motion.
The aim of the study is to find and perpetuate the
scheme of least waste methods of labour.
Workers do not enjoy making unnecessary or wasted
motions, as they result in needless fatigue.
Motion study thus helps in reducing fatigue & waste
motions.
Use of Time & Motion Study
Historically:
T&M Studies were used in the manufacturing industry to
evolve pay scales with the thought that money was the
only motivation for work.
Today:
T&M Studies can be effective for performance evaluations
T&M Studies can be used for planning purposes in order to
predict the level of output that may be achieved
T&M Studies can be used to uncover problems and create
solutions
T&M Studies can be used for time cost analysis
Objectives of Time & Motion Study
Estimation of realistic manpower
requirement.
Comparison of alternative methods of
working.
Establishment of incentive schemes
Improved control over operations.
Proper work distribution.
Future manpower and cost forecasting.
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Steps Involved in T&M Study
Selection
Obtain all necessary information
Divide the job into job-elements
Time each element
Number of cycles to be timed
Rate the operator
The rating of the operator to be objective
Make provisions for allowances.
Job Element
Should be as short as possible and should be
conveniently timed.
Should be unified and should have logical sequence
of basic motions.
Constant and variable elements should be separated
for generation of data for subsequent studies.
Regular and Irregular elements should be separated
so as to provide for time allowances.
Elements involving heavy and fatigue work should be
separated to allow for proper allowances.
Determination of Times
Standard Time
It is the time required
by an operator of average skill
who expends an average amount of effort and
is working under average conditions.
Use of Standard Time
To establish minimum performance requirements
Control of labour cost
Planning wage incentive schemes
Product line balancing.
Performance Rating
It is the pace of the actual work being done as a
percentage of the standard pace of doing the same work.
Level of Performance
It is the rate of output achieved by a qualified worker as an
average for the day.
Normal Time
It is the productive time needed to perform a task, utilizing
appropriate work methods, work area layout and
performing at a pace the firm defines as normal.
Actual Time
It is the time actually taken in completing the desired
task.
If the operator works at 100% efficiency then the
actual time would be equal to the normal time.
Use of Actual Time
In method study
In plant layout planning
In setting realistic starting and finishing times for
operator.
Allowance
Standard times for elements or jobs are necessary to
provide for allowances for compensating fatigue, personal
needs, contingencies, etc.
These are generally given as a percentage of the standards
time or normal time.
If allowance is given as a percentage of normal time
Standard Time = Normal Time (1+Allowance)
If allowance is given as a percentage of standard time
Normal Time = Standard Time (1 Allowance)
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Allowances or Time Allowances
Relaxation Allowance
For fatigue and personal
needs
Contingency Allowance
For duties of periodic
nature
Tools and Machinery
Allowance
For adjusting machines,
sharpening tools, etc.
Reject Allowance
Time used up in
producing items which
turn out to be defective
Interference Allowance
Stoppage of 2 or
machines
Excessive Work
Allowance
Due to unforeseen
temporary changes
Illustration 1
How many working minutes do you expect
would take a worker to produce a part for
which
the time standard is 10 minutes,
if the allowance for this work is 25% of the normal
time and
the worker is rated at 80%?
Click for Solutions
Solution to Illustration No. 1
Standard time = 10 Min
Allowance = 25% of N.T.
ST = NT (1+All.)
NT = ST / (1 + All.)
NT = 10/(1+25%)
NT = 8 Min
Performance Rating = (Normal
time) / (Observed time)
OT = NT / (Per. Rating)
OT = 8/(80%)
OT = 10 Min.
Standard time = 10 Min
Performance Rating = 80%
Actual time = ST/Per. Ratg
AT = 10/(80%)
AT = 12.5 Min.
Actual time = Observed time
*(1+All.)
OT = AT / (1+ All.)
OT = 12.5 / (1+25%)
OT = 12.5 X 4/5
OT = 10 Min.
Illustration 2
Calculate the standard production per shift of
8 hours duration, with the following data.
Observed time per unit = 5 minutes
Rating factor = 120%
Total Allowance = 33.33% of normal time.
Click for Solutions
Solution to Illustration No. 2
OT = 5 Min
Per. Ratg. = 120%
All. = 33.33% of NT
NT = OT * Per. Ratg.
NT = 5 X 120/100
NT = 6 Min.
ST = NT (1+ All.)
ST = 6 (1+33.33%)
ST = 6X4/3
ST = 8 Min.
8 Min. is needed for 1 Unit
1 Min. is needed for 1/8 unit
8 Hrs. is needed for 8 X 60/8
Units
8 Hrs. is needed for 60 units.
The standard production
per shift is 60 Units.
Methods of Time Estimation
Study of Past Production Records
It is an invaluable source of information regarding
the time taken to perform a particular task.
It is however assumed that the nature of activities
performed in the process does not change over
the period of time.
Estimation Method
It involves the analysis based on the experience &
judgment of the observer.
4/11/2013
Work Measurement Techniques
Direct Time Study Methods
Analytical Estimation
Work Sampling
It is based on statistical estimation of work during various time
samples.
Indirect Time Study Methods
Synthetic Timing Data
It is based on the previous data available with the establishment
which helps in synthesizing the overall data
Predetermined Motion Time Studies (PMTS)
It is based on the standard data available based on the various
micro motion studies.
Illustration 3
Calculate the standard time per article produced
from the following data obtained by a work sampling
study.
Total No. of observations = 2500
No. of working observations = 2100
No. of units produced in 100 hours duration = 6000
Proportion of manual labour = 2/3
Proportion of machine time = 1/3
Observed rating factor = 115%
Total allowance = 12% of normal time.
Hint
Hint for Illustration 3
Actual Working time in 100 hours = 100*2100/2500 = 84
Time taken per article = 84*60/6000 = 0.84 Min.
Observed Manual time = (2/3) * 0.84 = 0.56 Min.
Observed Machine time = (1/3) * 0.84 = 0.28 Min.
Normal Labour time = Observed Manual time * Rating Factor
= 0.56 * 1.15
Standard Labour Time = (0.56*1.15) * (1+ 12/100)
= 0.56*1.15*1.12
Standard time per unit = Standard Labour Time + Observed Machine Time
Illustration 4
After application of work simplification techniques and a
direct time study of elements the following time elements in
minutes were obtained as in table below.
Job
Element
Cycle
1 2 3 4 5
1 0.16 0.12 0.13 0.15 0.24
2 0.60 0.60 0.60 0.60 0.60
3 0.33 0.50 0.35 0.37 0.35
4 0.50 0.50 0.50 0.50 0.50
5 0.24 0.24 0.25 0.27 0.25
Illustration 4 (Contd.)
The following information was also determined about the job.
Job Element 2 & 4 are machine controlled and cannot be speeded up
by the operator
There were 2 irregular occurrences while timing.
The operator was rated at 110% when working.
Personal allowance 30 min/day; Unavoidable delays 20 min/day &
Fatigue 10% of the operators actual physical time.
Shift is 8 hour long.
Calculate standard time per unit & shift output standard.
Hint
Hint for Illustration 4
Identify the Irregular occurrences.
Calculate the average time for each job element.
Calculate Normal Time and then Standard Time by using the
data given for allowances.
Job
Element
Cycle Ave.
Time
1 2 3 4 5
1 0.16 0.12 0.13 0.15 0.24 0.14
2 0.60 0.60 0.60 0.60 0.60 0.60
3 0.33 0.50 0.35 0.37 0.35 0.35
4 0.50 0.50 0.50 0.50 0.50 0.50
5 0.24 0.24 0.25 0.27 0.25 0.25
Solution
4/11/2013
Solution for Illustration No. 4
OT
JE1
= 0.14
NT
JE1
= OT
JE1
X Per. Rat.
NT
JE1
= 1.4 X 110/100
NT
JE1
= 1.54
Similarly,
NT
JE3
= 0.385
NT
JE5
= 0.275
NT
manual
= 0.814
T
manual
= 0.814 * 1.10 = 0.8954
NT
total
= T
manual
+ T
machine
NT
total
=0.8954+0.50+0.60 =
1.9954
ST = NT
total
/ (1 Allowance
ST
)
Allowance = (30 + 20) / (8 * 60)
Allowance = 0.104167
ST = 1.9954 / (1- 0.1042)
ST = 1.9954 / 0.8958 = 2.227
min
Standard Time = 2.23 minute
Shift Output = 8 * 60 / 2.23
Shift Output = 215.25 Units.
Illustration No. 5
An operator manufactures 50 jobs in 6 hours
and 30 minutes. If this time includes the time
for setting the machine. Calculate the
operators efficiency. Standard time allowed
for the job is as follows.
Sr. No. Job Element Details
1. Setting Time 35 minutes
2. Production time per piece 8 minutes
Solution
50 Jobs in 6 hours and 30 minutes
50 Job in (6*60 +30) minutes = 390 minutes
Standard Time = Setting time+Production time
S.T. = 35 + 8*50 = 35 + 400 = 435 minutes
Per. Rating = Standard Time / Actual time
Per. Rat. = (435 / 390)*100 = 111.5%
Illustration 5
Time data taken for a bulk filling activity in Bangalore were recorded on a
continuous basis as shown below.
The firms labour contract requires a 15% allowance based on total time
for all workers on the bulk filling line
Compute the standard time for this activity.
Cycle Time (in Sec.) Rating
Factor
1 2 3 4 5
Grasp Bag 4 37 74 105 338 120
Locate for fill 16 51 84 117 352 120
Machine Fill 26 61 94 127 362
Set on Conveyor 34 68 102 334 369 110
Hint
Hint for Illustration No. 6
Cycle Time (in Sec.) Rating
Factor
1 2 3 4 5
Grasp Bag 4 37 74 105 338 120
Locate for fill 16 51 84 117 352 120
Machine Fill 26 61 94 127 362
Set on Conveyor 34 68 102 334 369 110
Grasp Bag 4 3 6 3 4 120
Locate for fill 12 14 10 12 14 120
Machine Fill 10 10 10 10 10
Set on Conveyor 8 7 8 207 7 110
Solution
Allowance = 15% on total time = 15% of Standard Time
Normal Time = (OT
1
XPer.Rat.
1
+ OT
2
XPer.Rat.
2
+OT
3
+ OT
4
XPer.Rat.
4
)
Normal Time = 4*1.2 + 12.4*1.2+10+7.5*1.1 = 4.8 + 14.88 + 10 + 8.25
Normal Time = 37.93 sec.
Standard Time = NT / (1 All.) = 37.93 / (1 0.15) = 37.93/0.85
Standard Time = 44.62 sec.
Cycle Time (in Sec.) Average
1 2 3 4 5
Grasp Bag 4 3 6 3 4 4
Locate for fill 12 14 10 12 14 12.4
Machine Fill 10 10 10 10 10 10
Set on Conveyor 8 7 8 207 7 7.5
4/11/2013
Further Numericals
Assuming that the total observed time for an operation of
assembling an electric switch is 1 minute. If the rating is 125%,
find normal time. If an allowance of 20% is allowed for the
operation for employee fatigue, determine the standard time.
Find out the standard time using the following data:
Sr. No. Job Element Details
1. Average time for machine element 7 min.
2. Average time for manual element 5 min.
3. Performance Rating 120%
4. Allowance (as a percentage of S.T.) 15%
For further details,
Contact:
AnupamKumar
Reader,
SMS Varanasi.
Email: anupamkr@gmail.com
Bibliography
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(Asia), 2003.
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Publication, 2008.
Chary, S.N., Productions and Operations Management, Third Edition, New Delhi: Tata McGraw Hill, 2004
Kumar Anil, S. and Suresh, N.. Production and Operations Management, New Delhi: New Age International
Publishers Second Edition, 2008.
Goel, B.S., Production Operations Management, Twenty Second Edition, Meerut, U.P.: Pragati Prakashan, 2010.
Kachru, U. Production and Operations Management: Text and Cases, New Delhi: Excel Books, 2007.
Rama Murthy, P., Production and Operations Management, New Delhi: New Age International, 2012.
Chunawalla, S.A., and Patel, D.R., Production and Operations Management, Mumbai: Himalaya Publishing
House, 2006.
Jauhari, V. and Dutta, K., Services: Marketing Operations and Management, New Delhi: Oxford University Press,
2010.
Verma, H.V., Services Marketing: Text and Cases, New Delhi: Dorling Kindersley, Pearson Education, 2009.

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