Training module on

Work Study & Productivity

By ILO

What is Productivity ?
Productivity is defined as ratio of Output to Input. It is used to measure the extent to which certain output can be extracted from given input

Example: A potter working 8 hours a day can produce 400 pots per month, with change of working method potter can produce 500 pots in a month with same equipment and hours of work. His productivity calculated by number of pots has increased by 25%

Factors Affecting Productivity

1. External Factors

a) Availability of Raw Materials, Skilled Labors, Taxation & Tariff policies by Government, Infrastructure, Money and interest rates
b) Beyond control of any employer

Factors Affecting Productivity

1. Internal Factors a) Land & Buildings in convenient location b) Materials Raw Material, Packing Materials, Auxiliary Materials such as solvents, lubricants, chemicals etc.

c) Machinery & Equipment's: Operational activity including transport handling, ACs, Compuers

Factors Affecting Productivity

1. Internal Factors
a) Land & Buildings in convenient location b) Materials Raw Material, Packing Materials, Auxiliary Materials such as solvents, lubricants, chemicals etc.

c) Machinery & Equipment's: Operational activity including transport handling, ACs, Computers

Factors Affecting Productivity

1. Internal Factors/Input Resources

d) Energy: In the form of electricity, gas, oil or solar power e) Human Resources: Men & women's to perform operational, Buy & sell, accounts, maintenance & administrative activities f) Another factor is capital or money which is indirectly included, as it is used finance purchase of land, machinery equipment, materials, labor and to pay services of Human Resource

The Task of Management

a) To coordinate above mentioned Input resources in best possible way to achieve highest productivity. b) In any organization one person or larger than one person business, coordinating and balancing these resources against each other.

The Task of Management

d) Efficiency minded management influences either one or both of the two factors and may be able to achieve larger quantity, better quality or higher value products or services with the same input. It may achieve better results by changing nature of input such as advanced technology, computers or by using alternative source of Raw material or energy

The Task of Management

Land & Buildings Materials Plants, Machines & Equipment's Energy Human Resources

Management
Obtains facts, Plans, Directs, Controls, Motivates In order to Produce

Products & Services

Work Study & Productivity

1. What Is Work Study
It is systematic examination of methods of carrying out activities so as to effectively utilize input resources and set up standards of performance for activities being carried out

2. Work Study & Productivity:

If work study results in 20% reduction in cycle time of a certain activity, by mere rearrangement of the sequence or simplifying method of operation without any additional expenditure, then productivity goes up by corresponding value

Total Time Of Operation

1. Work Content: Amount of work contained in a given product or process measure in work hours or machine hours 2. Basic Work Content:
Time taken to manufacture the product or perform an operation if the design or specification of product or services provided were perfect Is irreducible minimum time theoretically required to produce one unit of output

Total Time Of Operation

3. Excess Work Content:
Basic work content is ideal condition, which may never occur in practice, even though sometimes it may be approached in line manufacturing or process industries.

In general actual operation times are far in excess on account of excess work content

How Operational Time is Made Up ?

Basic Work Content

Basic Work Content of Product Or Operations

Total time Of Operation

A
B

Work Content Added by poor Product Design Or Material Utilization

Work Content Added by Inefficient Method Of Operations Ineffective Time Resulting from Human Resources Contribution

Total Ineffective Time

Total Time Of Operation

3. Excess Work Content:
a) Work Content Added By Poor Design or Specification of product or improper material utilization i. Poor Design Or Frequent Design Changes: Product requiring large number of non standard parts causing more assembly times High variety of products, Lack of standardization, so that work has to be produced in small batches with time lost in operator adjustments in shift to shift and batch by Batch.

Total Time Of Operation

3. Excess Work Content:
ii. Waste Of Materials: Product or its components or designed in such a way that excessive amount of material removal is required. Cutting operation in particular need to see if the resulting waste can be reduced or minimized

iii. Incorrect Quality Standards: Too high or too low quality standards causes excess work content. Too loose quality standard on other hand results in too many rejects

Total Time Of Operation

3. Excess Work Content:
iii. Incorrect Quality Standards: Deciding appropriate Quality Standard and Method of Quality Control is an Important Efficiency consideration b) Work Content Added By Inefficient Method Of Manufacture or Operations i. Poor Layout & Space Utilization Deciding appropriate Quality Standard and Method of Quality Control is an Important Efficiency consideration

Total Time Of Operation

3. Excess Work Content:
ii. Inadequate Material Handling Raw material, Work in process & Finished products are moved within and across departments. Advanced and efficient methods of material handling will save and time. III. Frequent stoppages as product changes from one product to another (Product Changeovers). Proper production and planning of batches will reduce number of product changeovers. Also lean technique such as SMED (Single Minute exchange of Die) will help to reduce Changeover Times.

Total Time Of Operation

3. Excess Work Content:
iv. Ineffective Method of Work By examining the way certain operations are carried out, better (Simplified) ways of doing work can be found out, ineffective time can be reduced. III. Poor planning of Inventory In many cases raw material is ordered in advance stocked in huge quantity before use. Similarly accumulation of Work in Process and finished product can also be seen on shop floors. This is case of tied up investment in inventory. Proper planning of inventory should minimize this without causing deficiency of materials

Total Time Of Operation

3. Excess Work Content:
iv. Frequent Breakdowns of Machines and Equipments Poor maintenance of machines and equipment may results machine and equipments out of action, causing low equipment or machine utilization. Preventive maintenance technique and systematic analysis of breakdown data will reveal the root causes

Total Time Of Operation

3. Excess Work Content:
c) Work content resulting mainly from contribution of Human Resources: I. Absenteeism & Lateness: If management is not able to provide safe, satisfying working environment then it results in absenteeism, lateness & deliberate slow working of workers.

II. Poor Workmanship: If workers are not properly trained, resulting poor workmanship causes rework and waste of material.

Total Time Of Operation

3. Excess Work Content:
III. Poor Workmanship: If workers are not properly trained, resulting poor workmanship causes rework and waste of material. IV. Accidents and Occupational Hazards: If management fails to provide safe and healthy working conditions, may result in accidents and occupational illness.

Summary : Basic and added work Content

Management Techniques To Reduce Ineffective Time

Thank you
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