Sie sind auf Seite 1von 66

Work Measurement Methods

Haleh Byrne
Product Lead Industrial Engineering
North Carolina State University
Industrial Extension Service
Campus Box 7902
Raleigh, NC 27695-7902

1-800-227-0264
Jobs, Innovation, Growth, Stability www.ies.ncsu.edu
If youre not keeping
score, you are just
practicing. - Vince Lombardi
2
WHAT IS WORK MEASUREMENT?

Work Measurement is determination of the


length of time it should take to complete a job

Systematic determination of the amount of effective physical and mental work in terms of work units in a
specified task.
3
General Steps in Work Measurement

Measure Work

Factor in Performance Rating

Factor in Allowances ( PF&D)

Develop Time Standards

Monitor, Improve, Update

4
WHERE DO WE USE TIME STANDARDS?
Product Costing

Delivery

5
WHERE DO WE USE TIME STANDARDS?

Capacity Analysis

Equipment Purchase Justification

6
WHERE DO WE USE TIME STANDARDS?

Efficiency Improvement Scope and Requirement

System Simulation

7
WHERE DO WE USE TIME STANDARDS?

Labor Requirements

Determination of Wage Payment Plans

8
WHERE DO WE USE TIME STANDARDS?

Benchmarking

Lean Six Sigma Application

9
WHERE DO WE USE TIME STANDARDS?

Labor Law Compliance

Union Contract Negotiations

10
UNPREDICTABLE
TIME
LACK OF UNPREDICTABLE
RESULTS
CORRECT INEFFICIENT
STANDARD ALLOCATION OF
RESOURCES
TIMES INACCURATE
OPERATION COST
ESTIMATES

11
The Whole Picture

Lean Six Sigma


Application
Focus on Time
assessment Work
and Measurement
management

Improved
Production
Planning &
Scheduling

Reduction
Increased of excess
capability to adapt inventory
customer demand
Reduction of
manufacturing
cost

13
Engineering & Lean Six Sigma Approach
PDSA Cycle

14
PDSA
Engineering & Lean Six Sigma Approach
for Work Measurement
IDENTIFY SCOPE
MODULES MEASURE

DEVELOP PROCESS FLOW MEASURE WORK- TIME


CHART AND MOTION STUDY
UNDERSTAND THE PROCESS APPLICATION
DEFINE VARIABLES COLLECT/RECORD
ASSESS NEEDED DATA
RESOURCES MONITOR OUTPUTS
SELECT MEASUREMENT CATEGORIZE THE
SYSTEM RESULTS
PLAN DATA COLLECTION
MODULES n
Pla

D
O
dy
A
C

t u
T

S
ASSESS AND
COMMUNICATE
OPTIMIZE
DATA ANALYSIS TIME
STUDY
IDENTIFY OPTIMIZED VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
DETERMINE RESOURCE DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
DOCUMENT COMMUNICATE RESULTS
STANDARIZED WORK FOR BUILD SIMULATION MODEL
FUTURE STATE

15
Plan
IDENTIFY SCOPE
MODULES MEASURE
Identify Scope Modules
DEVELOP PROCESS FLOW MEASURE WORK- TIME
CHART AND MOTION STUDY
UNDERSTAND THE PROCESS APPLICATION
DEFINE VARIABLES COLLECT/RECORD
ASSESS NEEDED DATA
Develop Process Flow Chart

RESOURCES
SELECT MEASUREMENT


MONITOR OUTPUTS
CATEGORIZE THE

SYSTEM
Understand the process
RESULTS
PLAN DATA COLLECTION
MODULES n
Define Variables Pla

D
O
Determine Work Measurement
approach
Assess needed resources
Create matrix and plan data
collection phase and modules

dy
A
C

t u
T

S
ASSESS AND
COMMUNICATE
OPTIMIZE
DATA ANALYSIS TIME
STUDY
IDENTIFY OPTIMIZED VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
DETERMINE RESOURCE DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
DOCUMENT COMMUNICATE RESULTS
STANDARIZED WORK FOR BUILD SIMULATION MODEL
FUTURE STATE

16
DO
IDENTIFY SCOPE
MODULES MEASURE

DEVELOP PROCESS FLOW MEASURE WORK- TIME


CHART AND MOTION STUDY
UNDERSTAND THE PROCESS APPLICATION

DEFINE VARIABLES
ASSESS NEEDED Measure COLLECT/RECORD
DATA
RESOURCES MONITOR OUTPUTS
SELECT MEASUREMENT CATEGORIZE THE
SYSTEM RESULTS
PLAN DATA COLLECTION
MODULES n Measure Work (time study,
Pla work sampling, etc.)

D
O
Collect and record data
Monitor outputs
Categorize the results

y
A

ud
C

t
T

S
ASSESS AND
COMMUNICATE
OPTIMIZE
DATA ANALYSIS TIME
STUDY
IDENTIFY OPTIMIZED VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
DETERMINE RESOURCE DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
DOCUMENT COMMUNICATE RESULTS
STANDARIZED WORK FOR BUILD SIMULATION MODEL
FUTURE STATE
17
Study Example
IDENTIFY SCOPE
MODULES MEASURE

DEVELOP PROCESS FLOW MEASURE WORK- TIME


CHART AND MOTION STUDY
UNDERSTAND THE PROCESS APPLICATION
DEFINE VARIABLES COLLECT/RECORD
ASSESS NEEDED DATA
RESOURCES MONITOR OUTPUTS
SELECT MEASUREMENT CATEGORIZE THE
SYSTEM RESULTS
PLAN DATA COLLECTION
MODULES n
Pla

D
O
Assess and communicate

Analyze the results


Validate Current approach
Determine resources
dy
availability
A
C

t u
T

SCommunicate results
Build simulation model
ASSESS AND(static
OPTIMIZE or dynamic) COMMUNICATE
DATA ANALYSIS TIME
STUDY
IDENTIFY OPTIMIZED VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
DETERMINE RESOURCE DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
DOCUMENT COMMUNICATE RESULTS
STANDARIZED WORK FOR BUILD SIMULATION MODEL
FUTURE STATE
18
Act
IDENTIFY SCOPE
MODULES MEASURE

DEVELOP PROCESS FLOW MEASURE WORK- TIME


CHART AND MOTION STUDY
UNDERSTAND THE PROCESS APPLICATION
DEFINE VARIABLES COLLECT/RECORD
ASSESS NEEDED DATA
RESOURCES MONITOR OUTPUTS
SELECT MEASUREMENT CATEGORIZE THE
SYSTEM RESULTS
PLAN DATA COLLECTION
MODULES n
Pla

D
O
Optimize

Identify optimized state of


parameters.
Determine and recommend
resource allocation, y
A

ud
C

t
T

S
scheduling, etc.
Document future state ASSESS AND
COMMUNICATE
standardized
OPTIMIZE work. DATA ANALYSIS TIME
STUDY
IDENTIFY OPTIMIZED VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
DETERMINE RESOURCE DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
DOCUMENT COMMUNICATE RESULTS
STANDARIZED WORK FOR BUILD SIMULATION MODEL
FUTURE STATE
19
Why Work Measurement?

To:

Assess Capabilities
Establish Expectations

20
Work Measurement Methods

SWAG
Estimation

Historical Data

Time & Motion


Direct Study
Work Measurement
Observation &
Techniques
Measurement
Work Sampling

MODAPTS

Predetermined
Time Systems MOST

MTM

21
Which Method?
VOLUME CYCLE TIME RECOMMENDED TECHNIQUE
LONG Work Sampling
1000'S MEDIUM Work Sampling, Time & Motion Study
SHORT PTSS

LONG Work sampling, Time & Motion Study


100'S MEDIUM Time & Motion Study, Work Sampling
SHORT PTSS , Time & Motion

LONG SWAG, Work sampling, Historical Data


10'S MEDIUM SWAG, Historical Data

SHORT Time & Motion Study

22
My employer has a implemented a lean initiative
over 4 years ago, yet has only a very rudimentary time
study. Actually, it is only a conversion from (inaccurate)
pay rates to time.
The result is waste has not been reduced from our
manufacturing operations. IIE Blog

Industrial Extension Service 23


The Cost of Work Measurement

24
Estimation

Historical
SWAG
Data

25
Estimation

Available Subjective
Quick Not a good source for time
No need for formalized standards
work measurement Inflated time due to delay and
program non-optimal performance
Less costly Difficult to set higher goals
Difficult to update standards
26
Observation

Time & Work


Motion Study Sampling

27
Time & Motion Study History

Business efficiency technique combining


Time Study work
(of Fredrick Winslow Taylor )
&
Motion Study work
(of Frank and Lillian Gilbreth)

28
Phases of a time study

Analysis

Measurement

Synthesis

Reporting and Standard


Update
29
Analysis
Phase

Obtain & record the following:

Operator
Working Conditions
Methods
Break Down the tasks to elements

30
Operator

Who do we study?

Normal Representative
& Qualified

31
Normal Operator

Adapted to the work and has sufficient


experience.
Has coordinated mental and physical abilities.
Maintains proper use of equipment and tools
related to the job.
Is cooperative.
Performs a pace best suited for continuous
performance. 32
(Adverse)Working Conditions
Missing tools and equipment

Inadequate Climate

Mental workload

Visual fatigue

Low level of worker participation

Inadequate equipment and workstation


33
Elements

An element is a distinct part of a specified job.

A work cycle is the sequence of elements which are


required to perform a job.

34
What is the Rule of Thumb?

The elements must be long enough to be accurately


timed .
The proper method should be used.
Human and machine must be separated.
The end point of each element should be consistently
detected.
35
Elements Categories
Non-Value Required but
Value Non-Value
added Added added

Manual or Manual or Manual or


Machine Machine Machine

Cyclic or Cyclic or Cyclic or


non-cyclic non-cyclic Non-Cyclic

Fixed Time Fixed Time Fixed Time


or Variable or Variable or Variable

Avoidable Avoidable Avoidable


or Non- or Non- or Non-
Avoidable Avoidable Avoid

36
37
Example

38
Jobs, Innovation, Growth, Stability www.ies.ncsu.edu
Measurement
Phase

Observe/record the tasks

Rate operator performance

40
How do we determine sample size?

Statistical method

Conventional method

41
Statistical Method of Sample Size

Accuracy desired
Confidence desired
Data variability

Formula
Provide an
example

42
Conventional Method for Sample Size

43
There are all kinds of factors that have to be
considered!!!!!!!

Dont just take any observed time.

Industrial Extension Service 44


Performance Rating

Westinghouse system

Synthetic rating

Pace rating

Objective rating

45
How Do We Performance Rate the
Operator?

Faster Operator 110%

Normal Operator : 100%

Slower Operator 90%

47
Allowances

Personal

Fatigue

Delays
Avoidable
Non-Avoidable

48
49
Direct observation
Actual Observation of current
practices- GEMBA
Open dialog with people that
perform the job
PROS Quick results
Actual utilization of the
operators
Work Load Evaluation
Requires continuous
maintenance
CONS
Does not lend itself to variety of
product mix

50
Direct Time Study Devices

Stop Watch Video


Camera

51
Time Study Steps
Observe and record information
Machine Set up
Operator Method Lay out Equipment Used Working Condition
(speeds & feeds)

Communicate
With operator With Supervisor All People involved in the process

Divide the operation


Divide Operation to Tasks Break tasks into elements

Determine sample size

Observe & document results

Rate the operator

Determine allowance

Develop Time Standard


52
Work Sampling
Observations about work are collected at discrete time
intervals, either periodic or random.

53
Work Sampling Steps

Identify the
Summarize,
Define Define the observers Collect Data
Design the analyze and
Operation task who will do (as per
study report the
Tasks elements the design)
results
Sampling

54
Observation

Actual Observation of current Requires


practices- GEMBA continuous
Work load evaluation maintenance
Open dialog with people that Does not lend itself
perform the job to variety of product
Quick results mix
Actual utilization of the
operators 55
PREDETERMINED TIME SYSTEM (PMTS)

Utilizes a Methods-Time Measurement that is used


primarily in industrial settings to determine the
standard time for completing an elemental task.

56
PMTS Procedures

MODAPTS
MOST
MTM

57
MODAPTS

"Modular Arrangement of Predetermined Time Standards"

58
MOST (Maynard Operation Sequence
Technique )

Parameters: Categories:

A= Action Reach
Distance Gain
B= Body Motion Move
G= Gain Control Place
P= Placement Return

59
MOST Procedure
Observe job/task

Determine
sequence(s) to use

Determine index
values

Add index values to


determine TMU

Multiply TMU by 10

Convert TMU to seconds,


minutes, hours
60
MTM (Methods Time Measurement)

MTM Categories
Reach
Move
Turn
Apply Pressure
Grasp
Position
Release
Disengage
Body Motions
Eye Motions

61
Industrial Extension Service
MTM Tables

62
PRE-DETERMINED TIME

Limited to hand, eye and


Efficient body motions
Reduced required time Process or machine times
Method Sensitive may not be established
Objective Approach Extra allowances are not
Applicable to Diverse Industries taken to account
Most widely used Not applicable to jobs with a
Enables to Develop Standards at planning high degree of control
stage Not economically feasible for
Not Sample Size Sensitive non- repetitive work
Detailed Time & Method Study
63
PRE-DETERMINED TIME

Hard to classify some motions


Difference in opinion between team
members
Variation in distance measurements
Repeatability and variation of worker
Very time-consuming to break up job
Repetitive to enter in data
May not match actual times

64
Time Study - Rules

Dont comment to the worker during the task

Stand (dont sit) beside the worker

Write every event (even though it may seems not


important)- If not caught on camera

Have a good position to observe/record

Stop the study if the worker seems to be under


pressure and it affects his/her work
Keys to Success

Involve
Employees
Have
Prepare and
information
Motivate
and manage
People
expectations

Success in
work
Measurement
Program
Benefits of Work Measurement

Common Currency for the evaluation and


comparison of all types of work.
Methods Improvement
Performance Standard provision
Allows for additional compensation for better
performance
Cost reduction by focusing on productivity
improvement & elimination of waste in the process
For the strength of the Pack is the Wolf,
and the strength of the Wolf is the Pack Rudyard Kipling

Industrial Extension Service 69

Das könnte Ihnen auch gefallen