Plant location is a strategic decision several factors influence this Plant Layout:

decision. The main objective of any business is to optimize its cost

and revenue that is, minimize its costs and maximize its returns. A technique of locating machines, processes and plant services
within the factory in order to secure the greatest possible output
of high quality at the lowest possible total cost of production.
The degree of significance for the selection of location for any
enterprise mainly depends on its size and nature large scale Type of Plant Layout:
industries requiring huge amount of investment there are many
considerations other than the local demand in the selection 1.Productor line layout: This type of layout is developed for
proper plant location these plants cannot be easily shifted to product-focused systems.
other place and an error of judgment in the selection of site can
be vary expensive to the organization. However, small-scale In this type of layout only one product, or one type of product, is
industry mainly selects the site where in accordance with its produced in a given area. In case of product being assembled, this
capacity; the local market is available for its products. It can easily type of layout is popularly known as an assembly line layout. The
shift to other place when there is any change in the market. work centers are organized in the sequence of appearance. The
raw material can treat one end of the line and goes from one
Factors affecting plant location: operation to another rapidly with minimum of work-in-process
• Nearness to Market: If the plant is located close to the market storage and material handling
the cost of transportation can be minimized. This also helps the
producers to have direct knowledge of the requirements of the 2.Process or Functional layout: This type of layout is developed or
customers. process focused systems.

• Nearness to supply of raw materials: As far as possible the site The processing units are organized by functions into departments
selected should be near the source of raw materials, so that the on the assumption that certain skills and facilities are available in
cost of transportation can be minimized and storing cost can be each department similar equipment and operations are grouped
reduced due to shorter lead time. together, e.g., milling, foundry, drilling, plating, heat treatment
etc. The use of process-focused systems is very wide in both
• Availability of labor: Availability of right kind of labor force in manufacture and other service facilities such as hospitals, large
required number at reasonable rates is also a deciding factor in offices, municipal services, etc.
selection of site.
3.Cellular or group layout: It is special type of functional layout in
• Transport and communication facilities: Generally, industries which the facilities are club bed together into cells.
have a tendency to locate the industrial units near the railway
station, highway or port areas. This is suitable for system designed to use the concepts, principles
and approaches of group technology‘. Such a layout offers the
• Availability of power and fuel: Coal, electricity, oil and natural advantages of mass production with high degree of automation
gas are the important sources of power in the industries. Ex: Tata even if the numbers of products are more with flexible
iron and steel industry is established near the coal mines of Bihar. requirement. In such a system the facilities are group into cells
which are able to perform similar type of functions for a group of
• Climatic conditions: Climatic conditions largely affect certain products.
production processes and also the efficiency of the employees. Ex:
Textile mills require moist climate that why these plant located at 4.Job Shop Layout: It is a layout for a very general flexible system
Mumbai and Ahmedabad. that is processing job production, The preparation of such a layout
is dependent on the analysis of the possible populations of orders
and is a relatively, complex affair
• Availability of water: Water is used in industries for processing
as in paper in chemical industries, for generation of power in 5. Projector Fixed position Layout: This is the layout for project
hydroelectric power, plants and also required for drinking sanitary type systems in which the major component is kept at a fixed
purpose also. position and all other materials, components, tools machines,
work etc. are brought and assembly or fabrication is carried out.
• Ancillary industries: Many industries such as processing and
assembly industries are not producing all the parts of their This type of layout is now not used very commonly as the
product but purchase some of the parts from ancillary industries machines required for manufacturing work are big and
producing it. complicated. The fixed position layout is used only when it is
difficult to move the major component and fabrication is to be
carried out. Ex: production of ships
Financial and other aids: For the development of backward
regions central as well as state government provide certain Principles of Plant Lay-out
incentives and facilities such as cash subsides, concession financial
assistance, land, power and other facilities at cheaper rates, tax 1. Principle of Integration
concession etc.
As a company grows, so too does its need for more systems and
applications each one playing a crucial function in its operations.
For example, you might have customer relationship management
(CRM) software to administer customer data, an accounting
system to handle invoices, and an HR system to manage
employees. But problems can occur if those systems aren’t
integrated. Teams may work or make key decisions based on
outdated data. One downside to batch manufacturing is processing costs can
increase because the process is slower than continuous flow.
So how can you ensure that everyone has access to the most up- Manufacturing processes that use certain materials like titanium
to-date information? And how can you integrate your systems to require the batch manufacturing approach. The continuous flow
ensure everything works together? process increases productivity due to manufacturing more
products in less time. Batch manufacturing allows you to develop
multiple products using one machine

What Is Business Process Integration? Continuous Flow Process

Business process integration (BPI) allows companies to connect The continuous flow process is a technique where products are
their people, data, and applications. With BPI, organizations can manufactured nonstop using one method at one facility without
better coordinate both internally and with partners, customers, break times. During the continuous flow process for a
and vendors to achieve better results. Processes become more pharmaceutical tablet production line, tablets move through the
complex as a company scales its operations. manufacturing process individually. Then, manufacturing experts
identify and correct tablet defects and other manufacturing
For example, managing purchase orders is easy enough for one problems early on in the process.
vendor. But as you work with more vendors, you might add
software to manage this process. Then you might add software to Batch Manufacturing
keep track of inventory, another to pay invoices, and another to
manage your accounts. Before long, a single process can end up Batch manufacturing in pharmaceutical tablet production lines
encompassing multiple technologies, which can affect involves developing tablets in groups using multiple steps. During
productivity and impede your automation efforts because the batch manufacturing, subsequent tablet batches must wait until
data is isolated from each other. 39% of I.T. and engineering the current batch is complete before production can move
leaders say that integrations and fetching external data are some forward. Then, the entire tablet batch goes to the final
of the biggest challenges they face in implementing process manufacturing stage together. In some batch manufacturing
automation. facilities, materials are shipped to another location between
steps, resulting in weeks or months between production times.

3 Types of Process Integrations

Continuous Flow Processes vs. Batch Manufacturing
Not every system integration is the same. There are different
types of integrations that allow systems to communicate with The main difference between continuous flow processes and
each other, which include: batch manufacturing is the number of products produced.
Because batch manufacturing involves processing multiple
• Native integrations: A native integration is when data seamlessly batches at once, it’s more difficult to assess quality control. This
flows between software applications. These integrations are often results in defect identification after the process is
already baked into the software, so the setup process is more completed. The continuous flow process makes locating and fixing
straightforward. You just need to allow permission between the product defects easier. Because products are completed
apps you want to connect. individually during continuous flow, examining the first product
and adjusting strategies if necessary ensure defect prevention
• API integrations: An API integration is when two or more early on in the process.
applications share data with each other through their application
programming interfaces (APIs). For example, you’d use a custom Continuous Flow Process Roadblocks
API to connect your online store with a payment processor to
accept orders if there are no native integrations. The continuous flow process is a superior solution for a wide
range of applications. However, manufacturing processes that use
• Third-party integrations: Companies with specialized needs certain materials like titanium require the batch manufacturing
often develop in-house software. But it’s often more practical to approach. Continuous flow can increase the risk of material
use an existing tool to add a specific feature. You could use third- contamination, but contamination risks can be mitigated with
party integrations in these cases instead of developing a feature proper process implementation and monitoring.
from scratch.
The Benefits of Using a Continuous Flow Process
2. Principle of Continuous Flow
For many applications, the continuous flow process has a variety
The continuous flow process is a technique where products are of benefits like:
manufactured nonstop using one process at one facility without ❖ Reduced or zero-waste operations
break times. ❖ Increased productivity due to manufacturing more products in
less time
Batch manufacturing in pharmaceutical tablet production lines ❖ Improved quality by identifying and fixing defects early on
involves developing tablets in groups using multiple steps. ❖ Increased stability
❖ Reduced lead times
 7. The flow of engineering

Using the continuous flow process also creates a work Companies who successfully integrate the principles of Lean
environment where your employees can get in the zone and Manufacturing understand that when each of these seven types
focus, allowing them to accomplish manufacturing goals more of flows are working in harmony, they are increasing their odds of
efficiently. There are minimal work-stopping problems with producing finished goods and services that require little to no
continuous flow because your team members don’t have to stall corrective action. Keeping production running, in such a smooth
or wait around for the next completed batch. Problem-solving is fashion, also helps to ensure that a company is creating
also more seamless with the continuous flow process. Your efficiencies.
employees can locate minor manufacturing issues before they
become costly problems that affect your bottom line. Barriers to Flow

3.Principle of Smooth Flow If you want to improve flow, first remove all barriers. Figliolino
Venanzio, Founder of Lean Six Sigma University, outlines both
It states that bottlenecks, congestion points and bulk tracking physical and intangible barriers to flow:
should be removed by proper line balancing techniques Examples of Physical Barriers to Flow:
. ▪ Distance: Rather than transporting individual items, they are
“Originally developed as a methodology to make production collected and shipped as a group
processes highly efficient, lean techniques have been adopted by ▪ Long Setup Times: When changing over tooling takes a long
more than 72 percent of machine shops across the country. For time, larger batches are run
many of these, the techniques have helped them to dramatically ▪ Batch-Oriented Machines: Some machines are designed to be
increase their competitive edge, while continuing to remove most efficient with large runs.
wasteful practices and contribute to the bottom line.” ▪ Poor Maintenance: Machines that break down frequently
disrupt flow.
Lean techniques are not limited to machine shops, productions
plants, or manufacturing companies. They can help any business
motivated to produce products and deliver services using as few Examples of Intangible Barriers to Flow:
resources as possible, while eliminating as much waste as
possible. No matter the type of business, whether a restaurant, • Unreliable Deliveries: When there is no trust that parts will
bakery, , small offices, or large processing plants all follow the arrive on time, extras are kept on hand
same five Principles of Lean from the Toyota Production System. •Unreliable Quality: If people think that many parts will be
unsuitable or will require rework, extras will be kept on hand
These principles are: • Approval Processes: The approver is seldom standing by, so
• Understand value from the customer perspective work is piled up until the next opportunity to get the go-ahead
• Understand the Value Stream • Lack of Faith: Some people just don’t believe flow is possible, so
• Make the Value Stream Flow don’t even try
• Create Pull • Resistance to Change: Some people think flow might work, but
like things to stay the same.
Once companies identify and prioritize all of the barriers to flow,
Continuously Improve each of these concepts is related to the they are ready to implement the changes designed to improve the
others. The focus of this blog is on flow, and the seven flows of overall process of flow.
manufacturing, barriers to flow in organizations, and how to
improve flow.
Improving Flow
Flow is how work progresses through a system. When a system is
working well, or having “good” flow, it tends to move steadily and Lee Candy, creator of Educational Business Articles, suggests 6
predictably, whereas, “bad” flow means the work starts and pointers to help companies develop flow within their processes:
stops. Every time there is a breakdown in the flow, chances of
accumulating waste increase. One goal is to strive for a consistent ✔ Map the process
flow which generates more reliable delivery, and greater value to ✔ Identify and log all problems process owners experience
customers, teams, and stakeholders.
✔ Identify all waste in the current process
✔ Map an ideal state – the perfect process achieved in absence of
all constraints
✔ Develop an action plan
Identifying the Seven Flows of Manufacturing
✔ Actively monitor the new processes put into place by creating
Mike Wroblewski, Senior Operations Consultant for Gemba performance measures
Consulting, explains in his reliable Plant blog, the Seven Flows of
Manufacturing by his Japanese sensei, Nakao-san:
4.Principle of cubic space: Space of a room, it the ceiling height is
1. The flow of raw material also utilized, more materials can be accommodated in the same
2. The flow of work-in-process space.
3. The flow of finished goods
4. The flow of operators
5. The flow of machines
6. The flow of information The concept of plant layout may be described as follows:
Plant layout is a plan for effective utilization of facilities for the (v) Principle of Overall Integration: All the plant
manufacture of products; involving a most efficient and facilities and services should be fully integrated
economical arrangement of machines, materials, personnel, into a single operating unit; to minimize cost of
storage space and all supporting services, within available floor production.
space. (vi) Principle of Safety: There should be in-built
provision in the design of layout, to provide for
“Plant layout is a plan of optimum arrangement of facilities comfort and safety of workers.
including personnel, equipment’s, storage space, material
handling equipment and all other supporting services along with
the decision of best structure to contain all these facilities.”
(iii) Principle of Interdependence: Interdependent
Certain useful observations on the concept of plant layout are as operations and processes should be located in
follows: close proximity to each other; to minimize
product travel.
(i) Plant layout is very complex in nature; because it (vii) Principle of Smooth Flow: The layout should be
involves concepts relating to such fields as so designed as to reduce work bottlenecks and
engineering, architecture, economics and facilitate uninterrupted flow of work throughout
business management. the plant.
(ii) Most of managers now realize that after the site (viii) Principle of Economy: The layout should aim at
for plant location is selected; it is better to effecting economy in terms of investment in fixed
develop the layout and build the building around assets.
it – rather than to construct the building first and (ix) Principle of Supervision: A good layout should
then try to fit the layout into it. facilitate effective supervision over workers.
(x) Principle of Satisfaction: A good layout should
(x) Hold down investment (i.e. keep investment at a lower level) in facilitate effective supervision over workers.
equipment. (xi) Principle of Satisfaction: A good layout should
boost up employee morale, by providing them
with maximum work satisfaction.

Objectives/Advantages of Plant Layout: Principles of Plant Layout-at a Glance

(i) Streamline flow of materials through the plant A technique of locating machines, processes and plant services.
(ii) Minimize material handling Within the factory order to secure the greatest possible output of
(iii) Facilitate manufacturing progress by maintaining high quality at the lowest possible total cost of production.
balance in the processes
(iv) Maintain flexibility of arrangements and of
operation
(v) Maintaining high turnover of in-process inventory Types of Plant Layout:
(vi) Effective utilization of men, equipment and space
(vii) Increase employee morale Two basic plans of the arrangement of manufacturing facilities are
(viii) Minimize interference (i.e. interruption) from – product layout and process layout. The only other alternative is
machine a combination of product and process layouts, in the same plant.
(ix) Reduce hazards affecting employees
1.Production line layout: This type of layout is developed for
Principles of Plant Layout: product-focused systems. In this type of layout only one product,
or one type of product, is producing a given area case of product
While designing the plant layout, the following principles must be being assembled, this type of layout is popularly known as an
kept in view: assembly line layout.

(i) Principle of Minimum Movement: Materials and The work centers are organized in the sequence of appearance.
labor should be moved over minimum distances; The raw material treat one end of the line and goes from one
saving cost and time of transportation and operation to another rapidly with minimum of work-in-process
material handling. storage and material handling.
(ii) Principle of Space Utilization: All available cubic
space should be effectively utilized – both
horizontally and vertically.
(iii) Principle of Flexibility: Layout should be flexible Following is an account of the various types of plant layout:
enough to be adaptable to changes required by
expansion or technological development. In this type of layout, all the machines are arranged in the
sequence, as required to produce a specific product. It is called
line layout because machines are arrange in a straight line. The
raw materials are fed at one end and taken out as finished
(iv) Principle of Interdependence: Interdependent product to the other end.
operations and processes should be located in
close proximity to each other; to minimize 2.Process or Functional layout: This type of layout is developed or
product travel. process focused systems. The processing units are organized by
functions into departments on the assumption that certain skills Product layout is suitable in the following cases:
and facilities are available in each department similar equipment
and operations are grouped together ,e.g., Milling, foundry, 1. Where one or few standardized products are
drilling, plating, heat treatment etc. The use of process-focused manufactured.
systems is very wide in both manufacture and other service 2. Where a large volume of production of each item has
facilities such as hospitals, large offices, municipal services, etc. to travel the production process, over a considerable
period of time.
3.Cellular or group layout: It is special type of functional layout in 3. Where time and motion studies can be done to
which the facilities are clubbed together into cells. This is suitable determine the rate of work.
for systems designed to use the concepts, principles and 4. Where a possibility of a good balance of labor and
approaches of group technology‘. Such a layout offers the equipment exists.
advantages of mass production with high degree of automation 5. Where minimum of inspection is required, during
even if the numbers of products are more with flexible sequence of operations.
requirement. In such a system the facilities are group into cells 6. Where materials and products permit bulk or
which are able to perform similar type of functions for a group of continuous handling by mechanical parts.
products. 7. Where minimum of set-ups are required.

4.Job Shop Layout: It is a layout for a very general flexible system

that is processing job production, The preparation of such a layout
is dependent on the analysis of the possible populations of orders Process Layout (or Functional Layout):
and is a relatively ,complex affair.
In this type of layout, all machines performing similar type of
5. Projector Fixed position Layout: This is the layout for project operations are grouped at one location i.e. all lathes, milling
type systems in which the major component is kept at a fixed machines etc. are grouped in the shop and they will be clustered
position and all other materials, components, tools machines, in like groups.
work etc. are brought and assembly or fabrication is carried out.
This type of layout is now not used very commonly as the A Typical Process Layout
machines required for manufacturing work are big and
complicated. The fixed position layout is used only when it is Advantages:
difficult to move the major component and fabrication is to be
carried out. Ex: production of ships. 1. Greater flexibility with regard to work distribution to
machinery and personnel. Adapted to frequent
Product layout is depicted below: changes in sequence of operations.
2. Lower investment due to general purpose machines;
Advantages: which usually are less costly than special purpose
machines.
1. Reduced material handling cost due to mechanized 3. Higher utilization of production facilities; which can be
handling systems and straight flow adapted to a variety of products.
2. Perfect line balancing which eliminates bottlenecks 4. Variety of jobs makes the work challenging and
and idle capacity. interesting.
3. Short manufacturing cycle due to uninterrupted flow 5. Breakdown of one machine does not result in
of materials complete stoppage of work.
4. Simplified production planning and control; and simple
and effective inspection of work. Disadvantages:
5. Small amount of work-in-progress inventory
6. Lesser wage cost, as unskilled workers can learn and 1. Backtracking and long movements occur in handling of
manage production. materials. As such, material handling costs are higher.
2. Mechanization of material handling is not possible.
Disadvantages: 3. Production planning and control is difficult
4. More space requirement; as work-in-progress
1. Lack of flexibility of operations, as layout cannot be inventory is high-requiring greater storage space.
adapted to the manufacture of any other type of 5. As the work has to pass through different
product. departments; it is quite difficult to trace the
2. Large capital investment, because of special purpose responsibility for the finished product.
machines.
3. Dependence of whole activity on each part; any
breakdown of one machine in the sequence may result
in stoppage of production.
4. Same machines duplicated for manufacture of
different products; leading to high overall operational
costs.
5. Delicate special purpose machines require costly Suitability of process layout:
maintenance / repairs.
Process layout is suitable in the following cases, where:
Suitability of Product Layout:
 1. Non-standardized products are manufactured; as the 2. There is no managerial problem, because of very less
emphasis is on special orders. number of workers, and small size of concern. Such
2. It is difficult to achieve good labor and equipment type of production requires less money and is easy to
balance. start.
3. Production is not carried on a large scale.
4. It is difficult to undertake adequate time and motion Disadvantages:
studies.
5. It is frequently necessary to use the same machine or 1. There is no scope for continuous production and
work station for two or more difficult operations. demand
6. During the sequence of operations, many inspections 2. As the purchase of raw materials is less, hence cost of
are required. raw materials per unit will be slightly more.
7. Process may have to be brought to work, instead of 3. For handling different type of jobs, only skilled and
“vice-versa”; because materials or products are too intelligent workers are needed increases
large or heavy to permit bulk or continuous handling
by mechanical means.

Batch production: This type of production is generally adopted in

medium size enterprise. Batch production is in between job
Combination Layout: production and mass production. Batch production is bigger in
scale than the job production. While it is smaller than that of mass
In practice, plants are rarely laid out either in product or process production, batch production requires more machines than job
layout form. Generally a combination of the two basic layouts is production and fewer machines that the of mass production.
employed; to derive the advantages of both systems of layout. For
example, refrigerator manufacturing uses a combination layout. Advantages:

Process layout is used to produce various operations like 1. While comparing with mass production it requires less
stamping, welding, heat treatment being carried out in different capital
work center’s as per requirement. The final assembly of the 2. Comparing with job production, it is more
product is done in a product type layout. advantageous commercially.
3. If demand for one product decrease then production,
for another product may be increased, thus the risk of
loss is very less.
Fixed Position Layout:
Disadvantages:
It is also called stationary layout. In this type of layout men,
materials and machines are brought to a product that remains in 1. Comparing with mass production cost of scales and
one place owing to its size. Ship-building, air-craft manufacturing, advertisement per unit is more.
wagon building, heavy construction of dams, bridges, buildings 2. Raw materials to be purchased are in less quantity
etc. are typical examples of such layout. than that in mass production; therefore it is slightly
costlier than that of mass production because less
quantity discount is available.

PRODUCTIVITY: is defined as the rate at which the goods and

services are produced. It refers to the relationship between the
inputs and the output. It is calculated as a ratio between the Mass production: This method of production is used by concerns
amount produced and the amount of resources (land, labor, where manufacturing is carried on continuously in anticipation of
capital, technology etc.) used in the course of production. demand though demand of the product may not be uniform
through the year. In mass production, simplification and
In other words, Method of Production: standardization of products are made with the help of specialized
(one purpose) machine, articles of standardized nature can easily
Job production: In this system, goods are produced according to and economically be produced on a large scale.
the orders with this method, individual requirements of the
consumers can be met. Each job order stands alone and is not There is a small difference between mass production and
likely to be repeated. This type of production has a lot of flexibility continuous production. This is mainly in the kind of product and
of operation and hence general purpose machines are required. its relation to the plant. In mass production plant and equipment
are flexible enough to deal with other products, involving same
Factories adopting this type of production, are generally small in production process. Where as in continuous or process
size. production only standardized product in a sequence produced. In
this method layout and requirement of additional tools and
equipment.

Advantages:

1. It is the only method, which can meet the individual Advantages:

requirement.
• A smooth flow of materials from one work station to the next in present process of doing the job is recorded sufficiently together
logical order. with all the relevant information, using the process chart symbols.
• Since the work from one process is fed directly into the next,
small in process inventories result Recording Techniques: The recording techniques are of three
• Total production time per unit short types
• Simple production planning control system are possible
• Little skill is usually required by operations at the production A.Process Charts:
line, hence training is simple, short and inexpensive.
Disadvantages: 1.Out line process chart: This chart outlines the main events
sequence wise considering only operations and inspections in the
1. A breakdown of one machine may lead to a complete given job. Ex: TASK
stoppage of the line that follows the machine. Hence
maintenance and repair is challenging job. Since the 2.Flow process chart: These are scale drawings of the work place,
product dictates the layout, changes in product design which indicate where each activity takes place. This chart is
may require major changes in the layout. capable of reflecting undue delays in transferring work between
workstations duplication of work, and unfair work assignment,
which may delay the completion process.

Work Study: Work study is one of the most important It classified into three types:
management techniques which is employed to improve the
activities in the production. The main objective of work study is to • Man Type : It records what the worker does.
assist the management in the optimum use of the human and • Materials Type : It records what happens to the materials.
material resources. • Equipment Type : It records how the equipment used.

Definition: Work study refers to the method study and work 3.Two handed process chart: The two hand process chart is a
measurement, which are used to examine human work in all its chart is which the activities of a workers hand are recorded, in
contexts by systematically investigating into all factors affecting their relationship to one another. It is commonly used for
its efficiency and economy to bring forth the desired repetitive and short operations
Improvement.
4.Multiple activity chart: A multiple activity chart is a chart in
Method Study: Definition: The systematic recording and critical which the activities of more than one item (worker, machine or
examination of existing and proposed ways of doing work, as a equipment) are recorded on a common time scale to show their
means of developing and applying easier and more effective inter relationship. By using separate vertical columns to represent
methods and reducing cost it is also called motion study. the activities of different operators or machines on a common
time scale, the chart shows very clearly the period of idleness on
Work Measurement: Definition: Work measurement is the the part of any items during the process
application of techniques designed to establish time for a
qualified worker to carry out a specified job at a defined level of
performance.
Work study is one of the most important management techniques
Work study has two parts, Method Study and Work Measurement. which is employed to improve the activities in the production. The
main objective of work study is to assist the management in the
Method study deals with the techniques of analyzing the way to optimum use of the human and material resources
do a given job better, Work Measurement seeks to measure the
time required to perform the job. Definition: Work study refers to the method study and work
measurement, which are used to examine human work in all its
contexts by systematically. Investigating in to all factors affecting
its efficiency and economy to bring for the desired improvement.
Basic procedure for Method Study:
Work Measurement: Work measurement is the application of
Select: The work to be studied Record: All the relevant facts of the technique to establish the time for a qualified worker to carry out
present or proposed method study by observation a specified job at a defined level of performance.
Examine: The recorded facts critically every thing that is done,
considering in turn, the purpose of the activity, the place where it Procedure for Work Measurement:
is performed, the sequence in which it is done, the person who is
doing it and the means by which it is done. 1.Sect: The work to be studied and determine the objectives of
Develop: The most practical, economical and effective method the study.
considering all the circumstances. 2.Record: All the relevant data relating to circumstances in which
Define: The new method so that it can always be identified. the work is being done, the methods to be used breakdown the
Install: The method as standard practice job into its elements
Maintain: That standard practice by regular routine checks. 3.Examine: The recorded data and the detailed breakdown
Recording: The current process of doing the job has to be critically to ensure the most effective method and motions are
recorded, while doing so every detail however small it may be, being used and that unproductive elements are separated from
has to be identified. Where the process is too long, involving productive elements.
many stages of production, inspection or transportation, the 4.Measure: The time required to complete each element using
the appropriate work measurement techniques and calculate the
time required to compete the work cycle which is known as basic
time.
5.Compile: The standard time for the operation or work place, in
case of stop watch time study the various allowances to cover
relation personal needs etc. are added to the basic time to
estimate the standard time.

1) Time study: It is defined as the art of observing and

recording the time required to do each detailed
element of all industrial operation.
2) Synthesis from standard data: This one technique of
work measurement to obtained synthetic times that
are synthesis from element times previously obtained
from direct time studies. The analysis and
measurement stage are thus conducted prior to the
actual study.
3) Predetermine motion time system (PMTS): Every
element of work is composed of some combination of
basic human motions. Apart from mental activity all
works can broken down into elements that usually a
fundamental movement of the body or body members.
After this analysis stage the basic motions that have
been isolated have a time allotted to them on the basis
of predetermine motion times.
4) Analytical estimation: Analytical estimating serves as
best for measuring work. In the analysis stage we find
the usually these basic elements or much larger as
compared to the elements in PMTS or time study. For
measuring stages the time, which will be occupied by
the element at a specific speed of working is
estimated.

5) Work Sampling: It is work measurement technique

which large number of instantaneous observation are
made random interval over a specified period of time
of a group of workers, machine and processes. Each
observation records what is happening at that instant
and the present observations recorded for a particular
activity or delay is a measure of the percentage of time
during which that activity or delay occurs. It can also
defined as a method of finding the percentage
occurrence of a certain activity by statistical sampling
and random observations.

Procedure for conducting time study: For conducting time study

average workers and average machines are selected. This study id
conducted by the time study expert, who should be familiar with
all the information related to the job and the conditions in which
it is being done.