INDUSTRIAL AND

MMFD 5043
WORK SYSTEM DESIGN

STANDARD OPERATING PROCEDURE (SOP) AND TIME STUDY ANALYSIS.

1.0 Introduction of SOP

SOPs detail the regularly recurring work processes that are to be conducted or followed within
an organization. They document the way activities are to be performed to facilitate consistent
conformance to technical and quality system requirements and to support data quality. They may
describe, for example, fundamental programmatic actions and technical actions such as analytical
processes, and processes for maintaining, calibrating, and using equipment. SOPs are intended to be
specific to the organization or facility whose activities are described and assist that organization to
maintain their quality control and quality assurance processes and ensure compliance with
governmental regulations. If not written correctly, SOPs are of limited value. In addition, the best
written SOPs will fail if they are not followed. Therefore, the use of SOPs needs to be reviewed and
re-enforced by management, preferably the direct supervisor. Current copies of the SOPs also need
to be readily accessible for reference in the work areas of those individuals actually performing the
activity, either in hard copy or electronic format, otherwise SOPs serve little purpose. (U.S.
Environmental Protection Agency, 2007)

2.0 Structure of SOP

Important information should include in the SOP are; SOP title/name, objective of the SOP,
the sequential order processes, details product, and last but not least safety precaution. A SOP can
be presented in different formats.
1. Simple Steps These are easy to write and follow and work well for short, simple,
straightforward tasks. It is used in processes that are fairly repetitive with very limited
decision making.
2. Hierarchical steps is an extension of the simple steps format, this format works better
for tasks that require additional detail or sub-steps within each primary step. It allows the
use of easy-to-read steps for experienced users while including more detailed sub-steps
as well.
3. Graphic Format This is a graphic version of the two previous formats. It works well for
tasks where activities must be done in a specific order and where an easy to follow
reminder at the job site is useful. The graphic format breaks long processes into shorter

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WORK SYSTEM DESIGN

sub-processes that consist of only a few steps. Workers can learn several short sub-
processes more easily than one long procedure
4. Flowcharts Format are simply a graphic way to present the logical steps in a decision-
making process. A flowchart provides an easy-to-follow mechanism for walking a worker
through a series of logical decisions and the steps that should be taken as a result.
(U.S. Environmental Protection Agency, 2000)

3. 0 Advantages of SOP

Below are some of the ways they can have a direct or indirect positive impact on business
performance:
1. SOPs will reduce system variation, which is the enemy of production efficiency and quality
control.
2. Well-written SOPs facilitate training. Having complete step-by-step instructions helps
trainers ensure that nothing is missed and provides a reference resource for trainees.
3. Well-written SOPs facilitate cross training. A SOP can be an excellent reference document
on how a task is done for employees filling in on jobs they do not perform on a regular
basis.
4. People tend to be supportive of the things they help create. Involving employees in
developing SOPs can help assure the final product is more complete, useful and accepted.
5. Employees can coach and support each other if there is documentation available on
exactly how various tasks must be done and everyone knows what their co-workers are
supposed to be doing. This can also help generate a more cooperative team approach to
getting all the daily tasks done correctly, every day.
6. Having well defined SOPs, using them in training and insisting that they be followed can
help keep employees safe at work and may provide some legal protection if an injury
occurs.
7. Having SOPs can encourage regular evaluation of work activity and continuous
improvement in how things are done.
(Grusenmeyer, 2001)

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WORK SYSTEM DESIGN

4.0 Example of SOP

SOP for Robinair Recovery Machine (Model Number 25175B)

PROCEDURE FOR NORMAL SYSTEM RECOVERY

1. Inspect the 25175B thoroughly to ensure that it is in good operating condition.
2. Make sure all connections are correct and tight
(see set-up diagram below).
3. Open the liquid port of the recovery cylinder (always open valves slowly to check hoses and
connections for leaks).
4. Make sure the Recover/Purge valve is set on Recover.
5. Open the output port of the 25175B
6. Open the liquid port on your manifold gauge set; opening the liquid port will remove the liquid
from the system first, greatly reducing the recovery time. (after the liquid has been removed,
open the manifold vapor port to finish evacuating the system).
7. Connect your 25175B to a 115V outlet.
a. Switch the main power switch to the ON position. You should hear the fan running.
b. Press the compressor start switch. This momentary switch will start the compressor.
It may be necessary, under certain circumstances, to press this switch more than once to
start the compressor.
8. Slowly open the input port on the 25175B.
a. If the compressor starts to knock, slowly throttle back the input valve until the knocking
stops.
b. If the input valve was throttled back, it should be fully opened once the liquid has been
removed from the system (the manifold gauge set vapor port should also be opened at
this time).
9. Run until desired vacuum is achieved.
a. Close the manifold gauge sets vapor and liquid ports.
b. Close the 25175B input port.
c. Shut off and proceed with the Self Purge procedure on the next page.

Note: Always purge the 25175B after each use (see Self Purge procedure on page 11). Failure to purge
the remaining refrigerant from the 25175B could result in the acidic degradation of internal
components, ultimately causing premature failure of the unit.

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WORK SYSTEM DESIGN

(ROBINAIR, no date)

This SOP using simple step format in their SOP structure. Each step with very simple verb and
explanation helps user to understanding the procedures. This SOP come with users operation
procedure. In the users operation procedure, the manufacturer included the important safety
information, care and maintenance, part diagram and graphical information.

5.0 Standard Operating Procedures to Assemble 13 amps Plug 3-Pin

Title : 13 amps Plug 3-Pin

Objective : The Worker should be able to assemble 13 amps Plug 3-Pin with standard
procedure.
13 amps Plug 3-Pin have 11 components:
1. Base Housing 2. Fuse
3. Top Housing 4. Right Side Cable Grip
5. Life Pin 6. Left Side Cable Grip
7. Neutral Pin 8. 3s Pin Screw
9. Earth Pin 10. Housing Screw
11. Fuse Holder

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WORK SYSTEM DESIGN

Table 1 :SOP to Assemble 3-Pin Plug Top 13 amps.

No Procedure Graphic
1 Insert and tighten the screw on the Earth Pin

2 Insert and tighten the screw on the Life Pin

3 Insert and tighten the screw on the Fuse Holder

4 Slot in Earth Pin on Base Housing.

Make sure slot in the pin in right direction.

5 Slot in Neutral Pin on Base Housing.

Make sure slot in the pin in right direction.

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WORK SYSTEM DESIGN

No Procedure Graphic
6 Slot in Fuse Holder on Base Housing

7 Slot in Life Pin on Base Housing

8 Slot in Fuse 13 amp on Fuse Holder

Make Sure Fuse 13 amp in good condition by checking their
continuity.

9 Slot in Right Cable Grip on Base Housing

10 Slot in Left Cable Grip on Base Housing

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WORK SYSTEM DESIGN

No Procedure Graphic
11 Install Top Housing on the Base Housing.
Make sure in right direction

12 Insert and tighten the screw.

6.0 Time Study Analysis

Table 2: Time Observations
Cycle Observed (in
Performance
No Job Element Second)
Rating
1 2 3 4 5
1 Insert and tighten the screw on the Earth Pin 8.5 9.0 8.3 7.9 8.0 105%
2 Insert and tighten the screw on the Life Pin 7.9 8.0 8.2 8.4 7.3 110%
3 Insert and tighten the screw on the Fuse Holder 7.5 6.9 6.9 8.3 9.1 105%
4 Slot in Earth Pin on Base Housing. 5.9 5.8 6.8 6.9 7.2 110%
5 Slot in Neutral Pin on Base Housing 5.6 4.9 5.6 6.1 6.0 110%
6 Slot in Fuse Holder on Base Housing 4.2 5.1 3.9 3.9 4.1 105%
7 Slot in Life Pin on Base Housing 3.4 5.1 4.1 2.5 3.1 120%
8 Slot in Fuse 13 amp on Fuse Holder 2.2 4.5 3.2 2.9 3.5 120%
9 Slot in Right Cable Grip on Base Housing 3.2 3.4 4.5 3.2 2.3 105%
10 Slot in Left Cable Grip on Base Housing 3.2 3.5 3.5 3.2 3.4 110%
11 Install Top Housing on the Base Housing.
3.5 3.2 3.3 3.6 3.3 105%
Make sure in right direction
12 Insert and tighten the screw. 8.3 9.0 7.9 8.6 8.2 120%
*Allowance Factor = 2%

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WORK SYSTEM DESIGN

1. Compute average time and normal time for each element

Table 3: Time Study Analysis

Normal Time
Average Performance
No Job Element (Average Time
times Rating
x PR)
1 Insert and tighten the screw on the Earth
8.3 105% 8.757
Pin
2 Insert and tighten the screw on the Life Pin 8.0 110% 8.756
3 Insert and tighten the screw on the Fuse
7.7 105% 8.127
Holder
4 Slot in Earth Pin on Base Housing. 6.5 110% 7.172
5 Slot in Neutral Pin on Base Housing 5.6 110% 6.204
6 Slot in Fuse Holder on Base Housing 4.2 105% 4.452
7 Slot in Life Pin on Base Housing 3.6 120% 4.368
8 Slot in Fuse 13 amp on Fuse Holder 3.3 120% 3.912
9 Slot in Right Cable Grip on Base Housing 3.3 105% 3.486
10 Slot in Left Cable Grip on Base Housing 3.4 110% 3.696
11 Install Top Housing on the Base Housing.
3.4 105% 3.549
Make sure in right direction
12 Insert and tighten the screw. 8.4 120% 10.08

2. Add the normal times to find the total normal time.

Total Normal time = 72.559 s.

3. Compute the standard time for the job.

Tstd = Tn (1 + Apfd)
Tstd = 72.559 (1+0.02) = 74.01018 s

7.0 References
Grusenmeyer, D. (2001) Developing Effective Standard Operating Procedures, PRO DAIRY - Cornell
University, pp. 17. doi: http://hdl.handle.net/1813/36910.
ROBINAIR (no date) Refrigerant recovery system users operating manual, (954).
U.S. Environmental Protection Agency (2000) Standard operating procedures, pp. 17. doi:
10.1038/nbt1106-1299.
U.S. Environmental Protection Agency (2007) Guidance document for the writing of standard
operating procedures, (April). Available at:
http://www.smu.ca/webfiles/SOPGuidanceDocument.pdf.