Method Study

Systematic Recording

? Critical Examination

Improvements
 Method Study
Three-dimensional approach…

Locating Faults

Improving Situation

Setting Standards
 Objectives of Method Study
Prime objective is to simplify the job by
developing more effective and economical
ways of doing it.
Supporting objectives (How to achieve
prime objective)…
• Better utilization of manpower and other
resources
• Elimination of unnecessary work.
• Reduction in unnecessary fatigue
• Identify bottleneck and try to minimize it
 Objectives of Method Study (Contd.)
• Bring standardization in operation
• Improve…

Process

Layouts and methods of MH

Working conditions

Designs (Product design and Scope of
inspections, specifications)

Safety standards
 How to achieve above objectives?
General practice of attacking any problem…

Data Collection
Critical Examination
Search for Alternative Solution
Evaluate and Select Solution
Develop and Install the Solution
Maintain and Control
Method Study Approach
Select
Record
Examine
Develop
Evaluate
Define
Install
Maintain
 Method Study Approach
1 Select
Factors affecting job selection for method study…
(a) Economic Consideration
“Thrust on returns from the method study”
• Critical /Costly/ Key profit generating operation e.g. in
casting industry “Melting” is a critical operation as well
as “Costly” operation.
• Operations with large scrape generation. For e.g. Sheet
metal (press work), metal removal etc.
• Labour intensive operations. E.g. cleaning of casting
(Chipping and Fettling) {Your fitting shop experience}
• Operation requiring large and repetitive M.H.
• Bottleneck Operation (Delivery get affected,
through put time increased etc)
 Method Study Approach (Contd.)

TOC: - “An Hour Saved on Non-bottleneck

Operation is not the Hour Saved for Entire
System, But An Hour Wasted (Lost) on Bottleneck
Operation is Definitely the hour wasted of Entire
System”

How to select such operation?

“Pareto Analysis”- “Trivial few Vital
many” - Small numbers of items among a
range of products/defects/causes/etc.
account for the highest value.
 Method Study Approach (Contd.)
(b) Technical Consideration
“Thrust is on taking the maximum advantages of
technological advancements”.

• Process automation
• Computerization of system
• Automated equipments/machines
 Method Study Approach (Contd.)
Instead of computerizing entire system, method study
exercise should be conducted first and then procedure
needing it will be computerized.

Two aspects need to be viewed…

1 Skill competence and expertise required for

certain operations, e.g. welding, decision making,
production scheduling, inventory control etc.
2 Technical limitations of process eg. frequent
tool breakage, poor surface finish after final
operations, and requiring advanced technology.
 Method Study Approach (Contd.)

(c ) Human Considerations
“Thrust is on handling the reactions people.”
• This aspect may reject operation qualified by first
two considerations.
• Operations which are..

Unsafe

More fatigue

Monotonous
 Method Study Approach (Contd.)
2 Record

 Record all the facts relating to the

existing method.
 The success of Method Study depends on
accuracy of this phase.
 This phase forms the basis for critical
examination and improvements
 Method Study Approach (Contd.)

Record
Charts Diagrams

Process Sequence Time Scale Movement

FD, SD,
TC,
OPC, FPC, TPC, MAC, SIMO
Cycle &
Chronocyclegraph
 Operation Process Chart / Outline
Process Chart (OPC)

“Bird’s eye-view of a process.”

Symbols used…

Operation

Inspection
 OPC (Contd.)
Procedure of Charting
• Numbering to start from the right, to the
point where the second component joins the
first
• The numbering sequence then transferred to
the next component on the left and
continues through its assembly to the first
component until the next assembly point.
 Record
Flow Process Chart (FPC)

1 Man type FPC:

Record of what worker does

2 Materials type FPC :

Record of how materials is handled/ treated/ moved

3 M/C type FPC:

Record of how machine & equipment is being used.
 FPC
Symbols used…

D
Operation Inspection Transportation Storage Delay
 Record
Flow Diagram
Representation of movements of worker or material on
drawing of plan of the workshop.

String Diagram
• Scaled plan/ model of workplace
• Worker’s path is traced and measured with thread.
• Material/ equipment also observed with specified
sequence of events.
• Usually preferred for worker’s movement
• Helpful in comparing two methods.
String Diagram
 Record
Two Handed Process Chart (TPC)
• Activities of a Worker’s hands /limbs are recorded in their
relationship to one another.
• Used for repetitive operations.
• Detailed recording compared to FPC since complete cycle is
short.
• One of the operations of FPC can be taken up for TPC.
• Symbols are slightly modified.

Multiple Activity Chart (MAC) / Man-Machine Chart

• Activities of more than one Subject recorded on common time
scale.
• Used to indicate interrelationship, generally “Man -Machine”.
• Useful in allocating work to operator in mass production,
maintenance etc.
• Useful in deciding maximum number of machines,
operator/operators can handle.
• Utility of man & machine can be worked out.
Two Handed Process Chart
 Record
Travel Chart
• It is a tabular record of movements of workers,
materials, or equipments between workstations for a
specific time.
• Used for larger number of movement, where string
diagram becomes clumsy.
• Generally used for office work.
Travel Chart
 Method Study Approach (Contd.)
3 Examine
Critical examination Technique
“Questioning Technique”

Primary questions Secondary questions

“Basic Information” “Examine basic information on PPSPM”
• Purpose
• Place
• Sequence
• Person
• Means
 Critical Examine
Primary Questions Secondary Questions
Aim… Aim…

(SCARE)
Simplify Evaluate possible
Combine alternatives and
Automate develop the best
Re-arrange method
Eliminate
 Critical Examine (Contd.)
Primary Question and Secondary Question

PURPOSE

What is done? PQ
Why is it done?
What else might be done? SQ
What should be done?
 Critical Examine (Contd.)
PLACE
Where is it done? PQ
Why is it done there?
Where else might it be done? SQ
Where should it be done?

SEQUENCE

When is it done? PQ
Why is it done then?
When might it be done? SQ
When should it be done?
 Critical Examine (Contd.)
PERSON
Who does it? PQ
Why does that person do it?
Who else might do it? SQ
Who should do it?

MEANS
How is it done? PQ
Why is it done that way?
How else might it be done? SQ
How should it be done?
 Method Study Approach (Contd.)
4 Develop
All “Should “ questions (last question of SQ)
can help evaluate present method’s short
comings and based on various requirements
(Functional, Dimensional and Process) new
method can be developed.

5 Evaluate
• Cost Benefit analysis of different proposed
methods.
• Quantitative as well as qualitative
evaluation
 Evaluate (Contd.)

Evaluation

Quantitative Qualitative

Employee morale
Financial Saving
Industrial relations
Improved productivity
Customer satisfaction
Space utilization
Job satisfaction etc.
 Evaluate (Contd.)
Evaluation Methodology (scoring and weighting)
Factor Weightage Ranking Final
Score
Increased 1 5 5
Output
Customer 5 3 15
Satisfaction
Space 2 2 4
Utilization
Total 24
 Method Study Approach (Contd.)
6 Define
Improved method as a result of evaluation need to be
defined precisely through…
• Charts, Diagrams
• Process Engineering formats
• Special tooling, jigs& fixtures etc.

7 Implement
• Managing Change
• Training and Negotiation
• Change-over schedule

8 Maintain
• Periodic Reviews
• Process audits etc