Unit II

Design of Work System: Work study: benefits, work study procedure; Method study:
objectives, method study procedure, process charts; Work Measurement (including
problems): benefits, techniques of work measurement: Time study, Synthesis Method,
Analytical estimating, PMTS, Work Sampling

Work Study:
“Work study is a tool or technique of management involving the analytical study of a job or
operation.” Work study helps to increase productivity.
Benefits of Work Study:
(i) Work study brings higher productivity;

(ii) Work study improves existing method of work for which cost becomes lower;

(iii) It eliminates wasteful elements;

(iv) It sets standard of performance;

(v) It helps to use plant and human more effectively;

(vi) It improves by saving in time and loss of material also.

Work Study Procedure:

(i) It selects the jobs which are to be studied;

(ii) It examines critically the recorded facts which are already done;

(iii) It records from direct observations all the matters which are happened;

(iv) It defines new method;

(v) It also installs the new method;

(vi) It also maintains the new standard;

(vii) It develops most economic and appropriate methods;

(viii) It measures the work content in the method, that is selected and compute a standard
time.
Types of Work Study:
1. Method Study:
According to ILO, method study is “the systematic recording, analysis and critical
examination of existing and proposed ways of doing work and the development and
application of easier and more effective method”. In short, it is a systematic procedure to
analyse the work to eliminate unnecessary operations.

Objectives:
(i) It improves the proper utilisation of manpower, machine and materials;

(ii) It also improves the factory layout, work place, etc.;

(iii) It also improves the process and procedure;

(iv) It develops better physical working environment;

(v) It reduces undesirable fatigue.

Process Charts:
Any manufacturing process can be better visualized by representing the process in the form
of a visual chart. These charts show how to manufacture the product in stages, the equipment
and tools that are planned to be used, and other activities like movement, quality
control checks, storages, etc.
Elements that may be included in a flowchart are a sequence of actions, materials or services
entering or leaving the process (inputs and outputs), decisions that must be made, people who
become involved, time involved at each step, and/or process measurements.
Types:
Macro motion chart
Operation Process Chart
Flow Process Chart
Two handed process charts
Multiple activity chart

Operation process chart

An operation process chart (OPC) represents the sequence of operations to be performed on a
component. It gives a bird’s-eye view of the various operations, inspections, and storage done
in sequence for all the components that go into a particular product or assembly.

Flow process chart:

Flowcharts are generally used in process industries to indicate the flow of the product during
various stages of the process. This is a combination of an outline process chart and the flow
diagram, where each operation is represented by the appropriate shape of the equipment.
There are three types of flow process charts and they are:
i) Flow Process Chart (Men).
ii) Flow Process Chart (Material).
iii) Flow Process Chart (Equipment).
The Flow Process Chart for Men records the activities of an operator.
The Flow Process Chart for Materials records what happens to the material with respect to
location and condition.
The Flow Process Charts for Equipment record the manner in which the equipment is used.
Two handed process charts:
The two-handed process chart gives a synchronised and graphical representation of the
sequence of manual activities of the worker. It is called two handed process charts since it
records the activities of the left hand and the right hand of the worker as related to each other.
A time scale can also be provided on the chart. This chart is used for repetitive works of short
duration.
This is also known as two handed process charts. It gives a synchronized and graphical
representation of the sequence of manual activities of the worker. This type of chart is used to
improve the motion sequence of an operator.
It is called two-handed process chart since it records the activities of the left hand and the
right hand of the worker as related to each other in a two-column chart by means of symbols
aligned representing the simultaneous movements of both hands appear opposite to each
other. The chart is used to minimize the unnecessary motions and to arrange the remaining
motions in an economical way.
Multiple activity chart:
A multiple activity chart is a tool that shows the activities of people or machines over time,
and how they relate to each other. It can be used to identify inefficiencies, improve workflow,
and plan team work.
The chart is a useful tool for understanding the flow of work in a cyclical process and as a
consequence understanding which resource is controlling the overall progress of the work. It
can also be used to describe any repetitive worker-machine system, as well as to investigate
potential process improvements apart from illustrating delays and redundancy, hence
ensuring process improvement efforts can be made to eliminate inefficiencies and identify the
activities that can be combined. The multiple activity chart can also be used to model
different scenarios to determine the optimum mix of resources for the work.

Work measurement:
Work measurement is a technique to determine the time it takes to complete a task. It
involves measuring the time required to perform a task, taking into account fatigue and
delays. The goal is to establish a standard time for the task.
Work measurement is the systematic process of determining the time required to complete a
task or job by a qualified worker using a defined method at a standard level of performance.
It involves techniques such as time study, predetermined motion time systems (PMTS), and
work sampling to establish standard times for various tasks, ensuring efficiency, productivity,
and cost control in industrial and service operations.
Benefits of Work Measurement
Work measurement provides several advantages for organizations aiming to improve
efficiency, productivity, and cost control. Here are some key benefits:
 1. Improves Productivity:
Helps identify inefficiencies in work processes.
Encourages employees to work efficiently by setting realistic performance standards.
2. Standardization of Work:
Establishes standard time for tasks, ensuring consistency in operations.
Reduces variations in performance and output quality.
3. Better Manpower Planning:
Helps in workforce allocation and scheduling.
Avoids overstaffing or understaffing, optimizing labor costs.
4. Cost Reduction:
Identifies unnecessary activities and bottlenecks, leading to cost savings.
Ensures accurate labor cost estimation for budgeting and pricing.
5. Enhances Work Design & Process Improvement:
Facilitates the redesign of jobs for better efficiency.
Helps eliminate non-value-adding tasks and streamline workflows.
6. Fair Wage & Incentive System:
Provides a basis for setting fair wages and performance-based incentives.
Motivates employees by linking pay with performance.
7. Effective Capacity Planning:
Helps in determining production capacity and resource requirements.
Ensures smooth operations without delays due to resource constraints.
8. Facilitates Performance Evaluation:
Assists in assessing employee performance objectively.
Helps managers set realistic targets and monitor progress.
9. Supports Automation Decisions:
Identifies tasks that can be automated for higher efficiency.
Provides data to justify investments in technology and equipment.
10. Enhances Customer Satisfaction:
Ensures timely production and service delivery.
Improves quality control and reduces defects.
By applying work measurement techniques, businesses can enhance overall efficiency, reduce
costs, and improve employee performance, leading to higher profitability and
competitiveness.
Work Measurement Techniques:
1. Time Study (Stopwatch Study)

2.Synthesis Method:
Definition: The synthesis method is a work measurement technique that determines the time
required for a task by combining pre-established standard times of smaller work elements.
Instead of conducting a new time study, this method uses previously recorded data from
similar tasks to estimate the total time needed.
Process of Synthesis Method:
1. Identify the Task Elements:
Break down the job into standard work elements (e.g., picking up a tool, assembling a part).
2. Retrieve Standard Data:
Use existing time study records or predetermined motion time systems (PMTS) to obtain
standard times for each element.
3. Sum Up the Element Times:
Add up the standard times of all elements to calculate the total time required for the task.
4. Apply Allowances:
Include allowances for fatigue, delays, and unavoidable interruptions to ensure realistic work
conditions.
Advantages of the Synthesis Method:

✔ Saves Time & Effort: Eliminates the need for repeated time studies.
✔ Improves Accuracy: Uses verified standard data, reducing errors.
✔ Useful for Planning: Helps in pre-determining job times for cost estimation and
scheduling.
✔ Reduces Study Costs: Avoids the expenses of conducting new stopwatch studies.

Disadvantages of the Synthesis Method:

Limited Flexibility: Not applicable if standard data is unavailable for new tasks.
Assumes Similar Conditions: Variations in work environment may affect accuracy.
Requires Standardized Data: The effectiveness depends on the quality of pre-recorded
data.

3.Analytical Estimation (Historical Data)

Analytical estimation is a work measurement technique used to determine the time required
for a task based on past experience, expert judgment, and historical data rather than direct
time studies. It is often used when precise measurement methods (like time study or PMTS)
are impractical, such as for non-repetitive, irregular, or complex tasks.
Process of Analytical Estimation:
1. Analyze the Task:
Break the job into elements or steps.
Identify key factors affecting task completion time (e.g., skill level, complexity).
2. Use Historical Data & Expert Judgment:
Refer to past time studies or industry benchmarks.
Consult experienced workers or supervisors to estimate time requirements.
3. Apply Adjustments & Allowances:
Consider environmental factors, worker efficiency, and job variations.
Add allowances for fatigue, delays, and contingencies.
4. Finalize Estimated Time:
Compare with similar tasks to ensure consistency.
Adjust the estimate as necessary based on real-time observations.
Advantages of Analytical Estimation:

✔ Quick & Cost-Effective: No need for extensive time studies.

✔ Useful for Unique or Non-Repetitive Tasks: Ideal for project-based work, maintenance,
and R&D.
✔ Leverages Experience & Expertise: Uses practical knowledge from skilled workers.

Disadvantages of Analytical Estimation:

Less Accurate Than Direct Measurement: Estimates may vary based on judgment.
Subjective Bias: Different experts may provide different estimates.
Dependent on Past Data: If no historical data is available, estimation becomes difficult.

4.Predetermined Motion Time Systems (PMTS)

Definition:
Predetermined Motion Time Systems (PMTS) are work measurement techniques that use pre-
established standard times for basic human motions (e.g., reaching, grasping, moving) to
determine the total time required for a task. These systems eliminate the need for direct time
studies and help in designing efficient work processes before actual production begins.
Key Features of PMTS:

✔ Uses predefined motion times for small work elements.

✔ Eliminates the need for stopwatch-based time studies.
✔ Helps in work design, planning, and process optimization.
✔ Provides consistent, accurate, and objective time standards.
Examples:
Methods-Time Measurement (MTM)
Work Factor System
MOST (Maynard Operation Sequence Technique)
5.Work Sampling (Activity Sampling)
Definition:
Work Sampling (also called Activity Sampling or Ratio Delay Study) is a statistical technique
used to estimate the proportion of time spent on different activities within a job. Instead of
continuously observing workers, random observations are made at different times to
determine how work is distributed.
Key Features of Work Sampling:
✔ Estimates Work Time Distribution: Determines the percentage of time spent on different
tasks (e.g., productive vs. non-productive work).
✔ Uses Random Observations: Observations are taken at random intervals, reducing bias.
✔ Best for Irregular or Non-Repetitive Work: Ideal for office work, maintenance jobs, and
managerial tasks.
✔ Requires Large Data Samples: The accuracy improves with the number of observations.
Process of Work Sampling:
1. Define the Study Objectives:
Identify the activities to be measured (e.g., machine operation, idle time, waiting).
2. Plan the Observations:
Select a representative sample of workers, machines, or processes.
Choose random observation times.
3. Conduct Observations:
At each scheduled time, observe and record what the worker/machine is doing.
Classify activities as productive, non-productive, or idle time.
4. Analyze Data:
Calculate the proportion of time spent on each activity using statistical formulas.
5. Interpret and Improve Efficiency:
Identify bottlenecks and optimize workflows.
Reduce non-productive time and improve resource utilization.