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Work Study
Definition by ILO : Is a generic term for techniques, particularly method study and work
measurement, which are used for the examination of human work in all its contexts, and which
lead systematically to investigation of all the factors which affect the efficiency and economy of
the situation being reviewed, in order to seek improvements.
Work study investigates the work done in an organization and aims at finding the best and the
most efficient way of utilizing the available resources (man, material, money and machinery) to
achieve best possible quality work in minimum possible time.
- which involves least possible time and causes least possible fatigue to the worker
Methods engineering grew out of the pioneering developments of the Gilbreths (Frank
B, and his wife, Lillian M.) who developed many of the tools of “motion study” as a part
of formulation a systematic approach to the analysis of work methods. Frank B Gilbreth
first become interested in methods analysis as an outgrowth of his observations of
brick-laying.
Gilbreth, who in 1885 was employed as an apprentice bricklayer, soon observed that a
journeyman bricklayer used one set of motions when laying bricks slowly, another set
when working at average speed, and still a different set when working at rapid speed.
As a result of his observations, he invented an adjustable scaffold and developed a set
of motions that greatly increased the number of bricks that could be laid in a day.
Some multiplant companies maintain both a central industrial engineering group to work
on problems common to many plants and also assign engineers to each plant to work
on projects pertinent only to that plant.
Charles E. Geisel States that in order to design a system (method) thoroughly, eight
elements must be considered.
To ensure that the optimum method is found, a systematic approach to methods design,
superior to the use of a ‘hit or miss’ method, is used. Stated in simplest form, this
approach consists of the following steps:
1. Analyze the problem: Identify the problem and then secure all known
information about it through the use of appropriate analysis techniques.
2. Question are present method. If a method presently exists, question the
details of the known information to determine the principles violated.
3. Synthesize a proposed method: Formulate a proposed method for
performing the work, embodying all the principles of sound methods
engineering.
4. Apply the proposed method: Standardize and apply the new method.
Process Chart
In those operations involving the combination of a person and a machine, a person and
several machines, or any combination of people and machines where delays are
prevalent, the multiple activity chart provides a convenient technique for analyzing the
combined activity. Very often the objectives of this type of analysis are to attain the
maximum utilization of a machine, to attain the optimum person to machine relationship,
or to bring about the best balance of crew activity.
For this reason, the time factor is an important consideration and necessitates the use
of a graphical representation involving time.
Use of Videotape
In the past, the experienced methods engineer found that one of the most important
aids was the use of motion pictures. There are many situations in which it is difficult to
observe all of the action taking place because of the high speed of activities or the
complexity of the operation.
Having observed slow-motion motion pictures, we are familiar with the fact that one can
take motion pictures at high speed and then, by projecting them at normal speed, slow
the action down. By the same token, we can take the pictures at slow speed and project
them at what appears to be high speed.
In using motion pictures, methods engineers may have had several objectives in mind.
First and foremost, they may have wanted a permanent record of the work as it was
being performed. Or they may have wished to use the film for analysis purposes,
commonly referred to as “micromotion” or “memomotion” studies, discussed in some
detail in sections that follow.
Micromotion Study
Micromotion study, which was originated by Frank B. Gilbreth, is one of the most
exacting forms of work analysis available for job improvement. It is an analysis
technique making use of motion pictures (or videotape) taken at a constant and known
speed. The film becomes a permanent record of both the method being used and the
time consumed in doing the work.
Although micromotion study formerly made use of motion pictures, very few companies
today are using them. As indicated earlier, videotape equipment has been developed so
extensively that it has virtually supplanted the use of the motion picture camera. Further
it is so cheap and easy to use that it makes the older approach archaic.
Micromotion study provides a valuable technique for making minute analyses of those
operations that are short in cycle, contain rapid movements, and involve high production
over a long period of time. Thus it is very useful in analyzing operations such as the
sewing of garments, assembly of small parts and similar activities.
Memomotion Study
Before leaving the general area of micromotion study, let us touch briefly on
memomotion study. Memomotion study, which was originated by M.E. Mundel, is a
special form of micromotion study in which the motion pictures or videotape are taken at
slow speeds. Sixty and one hundred frames per minutes are most common.
Memomotion study has been used to study the flow and handling of materials, crew
activities, multiperson and machine relationships, stockroom activities, department store
clerks, and a variety of other jobs. It is particularly valuable on long-cycle jobs or jobs
involving many interrelationships. In addition to having all of the advantages of
micromotion study, it can be used at relatively low film or tape cost (about 6% of the
cost at normal camera speeds) and permits rapid visual review of long sequence of
activities.
Through the pioneer work of Gilbreth, Ralph M. Barnes and other investigators, certain
rules for motion economy and efficiency have been developed. Some of the more
important of these principles are the following:
1. The movements of the two hands should be balanced and the two hands
should begin and end their motions simultaneously.
2. The hands should be doing productive work and should not be idle at the
same time except during rest periods.
3. Motions of the hands should be made in opposite and symmetrical
direction and at the same time.
4. The work should be arranged to permit it to be performed with an easy
and natural rhythm.
5. Momentum and ballistic-type movements should be employed wherever
possible in order to reduce muscular effort.
6. There should be a definite location for all tools and materials, and they
should be located in front of and close to the worker.
7. Bins or other devices should be used to deliver the materials close to the
point of use.
8. The workplace should be designed to ensure adequate illumination,
proper workplace height, and provision for alternate standing and sitting
by the operator.
9. Wherever possible, jigs, fixtures, or other mechanical devices should be
used to relieve the hands of unnecessary work.
10. Tools should be prepositioned wherever possible in order to facilitate
grasping them.
11. Object should be handled, and information recorded. Only once.
This has led to the contention of a number of social scientists that hobs need to be
enlarged or enriched. Feedrick Herzberg, one proponent of job enrichment, feels that
the purpose of job enrichment should be to eliminate the undesirable characteristics of
highly repetitive, specialized work by enlarging it to include:
Among the principles that commonly are applied in job enrichment programs, the
following are attended to by one large company.
Value Analysis
Value analysis is an objective study of every item of cost in every component part,
subassembly, or piece of equipment. This includes a study of the design, the material,
and the process in a continual search for other possible materials and new processes.
Value analysis involves the evaluation of an items function and relates its effect to the
end product. The purpose is to attempt to ensure that every element of cost contributes
proportionately to the function of the item.
As pointed out at the beginning of this chapter, modern industry is constantly searching
for better methods. When a business ceases to move forward, it will lost ground and
may eventually fail. It is for this reason that the major companies have organized
industrial engineering groups, work simplification and value analysis programs,
suggestion systems, quality circles, and other methods of achieving reduced costs of
manufacturing their products.
One of the consequences of these programs has been increased mechanization, which,
in turn, has led to the production of more and more goods per work hour. Among the
long-range benefits derived from this increased output have been higher real wages, an
improved standard of living, a shorter work week, and a reaction of the physical rigors of
the job.
--
Work Measurement – Establishing the time required by a qualified worker to carry out a
specified job at a defined level of performance
1. Process Charts
1. Outline Process chart (or operation process chart)
2. Flow Process chart (Man type; Material type; Equipment type)
3. Multiple activity chart
4. Two handed process chart (or Left hand-Right hand chart)
5. SIMO chart (Simultaneous Motion Cycle chart)
2. Diagrams
1. Flow diagram
2. String diagram
3. Cyclegraph
4. Chronocyclegraph
3. Models
i) Outline Process Chart – Gives bird’s eye view of the process; considers only main operations
and inspections
ii) Flow Process Chart – Detailed version of operation process chart shows the "OTIDS"
Operation (transforms or performs work that the customer may see as Value which is the product
or service Function at a Cost); Transport/Move; Inspection/Check; Delay/Wait and Store/File.
Recent "OTIDS" have adde anoth D being Decision to become "OTIDDS". The use of "Value
Stream Maps" in "Lean" (John Krafcik a research student at MIT in late 1980's) are enhanced for
each major step in the Value Stream by using the Flow Process Chart to provide more details on
the value and non-value activities in the Stream. Value Analysis/Value Engineering and Process
Failure Mode and Effect Analysis techniuques in the Automotive qualkity and technical
specificvation (ISO TS16949:2002) and Boeing Aircraft Corporation Quality Tools Manaul all
use Flow Process Charts
iii) Multiple Activity chart – Activities of more than one man or machine are recorded on a
common time scale
iv) Two handed Process chart – Activities performed by two hands of worker are recorded on a
common time scale
v) SIMO chart – Detailed version of two handed process chart (micromotion study)
vi) Flow diagram – Shows the relative position of machines and equipments and marks the path
followed by man and material
vii) String diagram – similar to flow diagram except that path is traced by a continuous string or
thread
A small electric bulb is attached to hand and photograph is taken by a still camera
ix) Chronocycle graph – Similar to cycle graph except that along with path it also shows
direction and speed of movement. This is done by interrupting the light source so that path
appears as a series of dots.
Memo Motion study involves time-lapse photography ie a still camera takes pictures of the
activity at regular intervals (1 to 5 sec) unlike micromotion study which involves making a
continuous motion film
Memo motion study is used for activities which are not required to be examined in fine detail but
are still too fast to be recorded accurately by human eye.
Therbligs – are the fundamental hand motions which are performed over and again in any
manual work, eg Search, find, select, hold, grasp, use, assemble, dissemble, inspect, release
-developed by Mr. Gilbreth (Therblig is his name spelled backward) -used in micromotion study
Work Measurement
Std. time for any job may be established by 3 methods:
Time Study (stop watch) Short cycle ; Repetitive jobs Work Sampling Long cycle ;
Heterogeneous operations PMTS Short cycle ; Highly-repetitive jobs
Work sampling
Time
study
Synthetic time
P.M.T.S.
Analytical
estimating
Direct
Indirect
Work
Measurement
Work Sampling
In this a no. of observations are made over a period othat instant. The percent of observations
recorded for a particular activity is a measure of the percentage of time during which that
activity occurs.
Work Sampling is used for activities of very long duration which cannot be measured with
stopwatch. Eg to find out actual working time of an operator in one shift.
No. of observations required for 95% confidence level and ±5% accuracy (ie we are sure that
95% of the time the average value will not be having error more than 5% of the true value.
---------------
(A = Accuracy required)
A2
StopWatch TimeStudy
Why do we break down the activity to be studied into elements?(why not measure time
straightly)
Rating – Comparing the pace rate or performance of a worker against standard performance level
Rating techniques-
However assigning a rating factor and allowances are largely subjective in nature and depends on
personal judgment of timestudy engineer
Allowances- it is the additional time provided over and above normal time to take into account
time for relaxation, attending personal needs
Rest and personal allowances (to overcome fatigue incurred during working)
Interference allowances (to take into account m/c stoppages etc)
Special allowances (for activities which are generally not a part of work cycle)
In this we build up the total time for a job by summing up the times for different elements
Particularly useful for operations which are still in the planning phase and have not yet
started (helpful in planning and scheduling)
Synthesis
PMTS (Predetermined Motion Time System)
Analytical estimating
Synthesis
Element time values are taken from a catalogue of elements time built from timestudies
done in the past
PMTS also make use of previously collected data but it deals with basic human motions (or
therbligs) of duration 0.1 seconds or less. Whereas in synthesis duration may be 3-4 seconds
Analytical estimating is used when past time data is not available and estimator has to rely on his
past experience.
PMTS
Analytical Estimating
Comparison
Work sampling is used for long cycles eg amount of time actually spent working by a worker in
a shift
Time study is used for short repetitive cycles eg worker working on a assembly line
[[Bold]] textPMTS is used for very short cycles which require a very detail analysis
(micromotion study)
Time
study
Work sampling
Synthetic time
P.M.T.S.
Analytical
Time Required
MAX
MIN
Accuracy
MAX
MIN
That’s why I picked up the cause in my final year project and developed a software which
automates the process of time & motion study.
http://in.geocities.com/time_motion_study
http://www.professays.com/faq/
A process chart giving an overall picture by recording in sequence only the main operations and
inspections
Amount of Details
(ii) Inspection
Application
When operation activities are subject to frequent changes or a more detailed analysis
Outline Process Chart for Repairing a Punctured Scooter
Some Conventions in Outline Process Chart
Activity 2 and inspection 1 occurs four times, but the number used in repeat line is always
one less than the total as the first occasion is already plotted before the repeat break (Hence
the (n-1) rule)
Symbols showing duplicate operation 2
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A Two-Handed Process Flow Chart individually shows the movement of each hand in a manual
process. It is typically used when analyzing a manual assembly process, to help make it easier to
perform.
Fig(Two-Handed Process Flow Chart)
It is a more detailed type of movement chart in which the recorded details are like:
It is a tabular record for presenting quantitative data about the movement of workers, materials or
equipment between any number of places over any given period of time.
Amount of Details
Application
For studying layout problem in deciding how to minimize total flow (of material) in the plant or
work-place.
Travel Chart
Amount of Details
Limited to plot against a common scale (of time) for few types of activities like operation,
idleness, delay, etc.How to construct
(i) Start with the preparation of flow process chart for elements like machine or operative
involved in the process.
(iii) Take sufficient observations of time-study for determining accurate elemental time.
(iv) draw in the form of bar-chart for each activity of the leading operative or machine. Take a
common scale such as time for each activity.
(v) Use different colour codes for different sections within each bar.
(vi) calculate the amount of effective work per cycle in percentage of total time.
Application
(i) For preliminary investigation to study the extent of accuracy of particular activities
(ii) Helps in balancing activities
(i) Helps in exploring the possibilities of elimination, change in work sequence, combination and
simplification of work elements.
Email Based Homework Assignment Help in Questions on Travel Chart
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submit your school, college or university level homework or assignment to us and we will make
sure that you get the answers you need which are timely and also cost effective. Our tutors are
available round the clock to help you out in any way with industrial management.
Live Online Tutor Help for Questions on Travel Chart
Transtutors has a vast panel of experienced industrial management tutors who specialize intravel
chart whocan explain the different concepts to you effectively. You can also interact directly
with our industrial management tutors for a one to one session and get answers to all your
problems in your school, college or university level industrial management. Our tutors will
make sure that you achieve the highest grades for your industrial management assignments. We
will make sure that you get the best help possible for exams such as the AP, AS, A level, GCSE,
IGCSE, IB, Round Square etc.