Taif University College of Engineering
WORK STUDY
8053203-3
Lecture Notes
Draft
Industrial Engineering Program
WORK STUDYCourse ID 8053203-3
Lecture [2 ]
Method Study design
or Motion Study
(how should a job be done?)
Content
Objectives of methods study
Procedure for Method study design (motion study)
Studying each of Procedural steps one by one
In the next four weeks we are going to study ;
Method Study
(Motion study)
(how should a job be done)
Work Study (Time and Motion study)
(a) Method Study or Motion Study (how should a job be done)
It is the systematic recording and critical examination of existing
and proposed ways of doing work, as a means of :
1) improving the present method, achieving the best method ,
Developing and applying the best, easier, economical, safe , less
effort and more effective methods of performing each operation
2) To /eliminate wastage so that production increases with less
fatigue and reduced costs.
for example by :
(a) eliminating unnecessary movements of workers , tools machines
production lines helps to improve the current production methods, also
(b) changing the sequence of operation can help improve the productivity
Objectives of methods study
To study the existing / proposed method of doing any job or activity.
To develop an improved method to enhance productivity and to
reduce operating cost.
To reduce excessive material handling movement and thereby reduce
fatigue of workmen.
To improve utilization of workers.
To eliminate wasteful and inefficient MOTIONS.
To standardize work methods or processes ,working conditions,
machinery, equipment and tools.
Method Study or Motion Study
(how should a job be done)
Method Study Can be divided into two areas:
(a) Methods analysis and
(b) Methods design.
(a) Methods analysis
is concerned with the study of an existing method or process.
Objectives:
Eliminate unnecessary and non-value-adding work elements
Combine elements and operations
Rearrange elements into more logical sequence
Simplify remaining elements and operations
Method Study Can be divided into two areas:
(a) Methods analysis and
(b) Methods design.
(b) Methods design
is concerned with either of the following situations:
1. Design of a NEW method or process
Required for new product or service and there is no
existing standard
Method must be designed from scratch, using best
existing practice for similar operations
2. Re-design of an existing method or process based on a
previous methods analysis.
How to apply methods study (motion study)
Systematic Approach
(Procedure ) for
methods study design
(motion study)
How to apply methods study design?
There exist a Systematic Approach (Procedure ) in
Methods study design
has its basis in the scientific method used in science,
research and development, engineering design, and
other problem areas.
The systematic approach consists of the steps
described in next slides.
Methods study design,
is a form of
creative problem solving
Examples on When and why to apply
methods study design
The problem to solve, in methods study design may be
(a) low productivity,
(b) high cost,
(c) inefficient methods, or the need for a new method
or a new operation.
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation ) to be studied/analyzed
and define objectives to be achieved by method study.
(2) Record all relevant facts or information pertaining to the existing
method using the recording techniques such as:
(a) Operation process chart (b) Flow process chart
(3) Examine all the recorded data information (critically
questioning; purpose, place ,sequence ,person and the means of
doing the job/process/ operation.)
(4) Modification and improvements in current data ( which
method is practical and economical to find /Develop new or alternative
or best method under prevailing circumstances
(5) Measure the work content and establish the standard time using
an appropriate work measurement technique
(6) Define new method(s) for the job/process/operation
(7) Install and maintain the new method to achieve
Procedure for Method study design (motion study)
Let us study each of
these steps
one by one
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation/station ) to be
studied/analyzed and define objectives to be achieved by method
study.
While selecting a job for doing method study, the following
factors are considered:
(a) Economical factors.
(b) Human factors. let us study each
factor in next pages
(c) Technical factors
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation/station )
continued in
(a) Economical factors. next page
The money saved as a result of method study should be
sufficiently more. Then only the study will be worthwhile.
Based on the economical factors, generally the following jobs are
selected.
(a) Operations having bottlenecks (which holds up other production activities).
(b) operation with poor use of resources ( materials, labour , machines|) resulting
in high scrap or reprocessing costs
(c) Bad layout or operation planning : e.g. materials are moved for long distance.
(d) Operations done repetitively.
(e) high risk jobs
(f) Operations having a great amount of manual work.
(g) Excessive overtimes ( overtimes are required to produce what is needed)
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation/station )
(a) Economical factors.
Now, when selecting any of the up mentioned , the question
is whether one of the following changes will occur
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation/station )
(b) Human factors.
The method study will be successful ONLY with the co-
operation of ALL people concerned viz., workers, supervisor,
trade unions etc.
Workers may resist method study DUE TO :
1) The fear of unemployment.
2) The fear of reduction in wages.
3) The fear of increased workload.
Then if they DO NOT accept method study, the study should
be postponed.
Procedure for Method study design (motion study)
(1) Select the work or (job/process/operation/station )
(c) Technical factors
To improve the method of work all the technical details about the
job should be available.
(a) Every machine tool will have its own capacity. Beyond
this, it cannot be improved.
(b) repairs and maintenance
For example,
a work study man feels that speed of the machine tool may be increased and HSS
tool may be used. But the capacity of the machine may not permit increased
speed. In this case, the suggestion of the work study man cannot be implemented.
These types of technical factors should be considered.
Procedure for Method study design (motion study)
(2) Systematic Record all relevant facts , details or information
pertaining to the existing method of doing the work
This is done by directly observing the work
Symbols are used to represent the activities like operation, inspection,
transport, storage and delay.
The recording techniques used include:
a) Operation process chart b) Flow process chart
c) Man-Machine chart d) Multiple activity chart
e) Simultaneous motion chart f) Motion chart g) Film analysis chart
information pertaining to the existing method include:
The recording techniques used in method study
Types and classifications
Procedure for Method study design (motion study)
(3) Examine ALL the recorded data information
This step comes after the method is recorded by suitable charts and
diagrams.
Critical examination is done by questioning technique.
The individual activity (operation//process /Job) is critically examined
(questioned ) by putting a number of questions , using TWO sets of
questions:
a) Primary questions (answers to these questions show up the
necessity of carrying out the activity), &
b) Secondary questions (answers to these questions allow to
determine whether possible to alternative methods of doing the
activity are practical and preferable )
Answering these questions will result in the development of a better
method
Primary questions
The used questioning sequence follows a well-established pattern
which examine the following
To eliminate the activity, if possible
To combine or re-arrange the activities
To simplify the activity
answers to these next questions show up the NECESSITY of carrying out THE ACTIVITY,
Primary questions
questioning sequence following well-established pattern
Secondary questions
answers to these questions allow to determine whether possible to
alternative METHODS of doing the activity are practical and preferable
these questions , in the shown sequence
must be asked systematically every time a
method study is undertaken
Example: see textbook page 97
explained in Details example
About : Examine all the recorded data information
Procedure Method study design (motion study)
(4) DEVELOP : Modification and improvements in current
data which method is practical and economical to find
/develop new OR alternative OR best method under prevailing
circumstances
The factors to be considered While evaluating alternatives
and selecting the best method
a) Cost of implementation
b) Expected savings in time and cost continued in
next page
c) Feasibility
d) Producibility
e).Acceptance to design, production planning and control,
quality control, production and sales departments
f) Reaction of the employees to new method
g) Short term or long term implication of alternatives
Procedure Method study design (motion study)
(4) DEVELOP : Modifications and improvements in current
Procedure Method study design (motion study)
(5) Measure the work content and establish the standard time
using an appropriate work measurement technique
(6) Define new method(s) for the job/process/operation
Once a complete study of a job has been made and a new method is
developed, it is necessary to obtain the approval of the management
before installing it.
The work study man should prepare a report giving details of the
existing and proposed methods.
study man should give his REASONS for the CHANGES suggested.
continued in
next page
Procedure Method study design (motion study)
(6) Define new method(s) for the job/process/operation
The REPORT should show
(a) Brief description of the old method.
(b) Brief description of the new method.
(c) Reasons for change.
(d) Advantages and limitations of the new method.
(e) Savings expected in material, labour and overheads.
(f) Tools and equipment required for the new method.
(g) The cost of installing the new method including.
(1) Cost of new tools and equipment.
(2) Cost of re-layout of the shop.
(3) Cost of training the workers in the new method.
(4) Cost of improving the working conditions.
Procedure Method study design (motion study)
( ) Install and maintain the new method to achieve
This step is the most difficult stage in method study
Here the active support of both management and trade union is
required.
Here the work study man requires skill in getting along with other
people and winning their trust.
The install stage consists of
(a) Gaining acceptance of the change by supervisor.
(b) Getting approval of management.
(c) Gaining the acceptance of change by workers and trade unions.
(d) Giving training to operators in the new method.
(e) To be in close contact with the progress of the job until it is
satisfactorily executed. continued in
next page
Procedure Method study design (motion study)
(7) Install and maintain the new method to achieve
The maintain stage
The work study man must see that the new introduced method is followed.
The workers after some time may slip back to the old methods. This should
not be allowed.
The new method may have defects. There may be difficulties also. This
should be rectified in time by the work study man. Periodical review is
made.
The reactions and suggestions from workers and supervisors are noted. This
may lead to further improvement.
The differences between the new written standard practice and the actual
practice are found out. Reasons for variations are analyzed.
Changes due to valid reasons are accepted. The instructions are suitably
modified.
Interactive discussion
1)
2)
THANK YOU
ANY
QUESTIONS?
References
http://fmcet.in/MECH/ME2027_uw.pdf
https://www.youtube.com/watch?v=i0U02kd2ZnE
https://www.youtube.com/channel/UC_sNy2oKNAEdhKO0Q-
H9MPA/search?query=work+study
https://www.youtube.com/channel/UCb9okJF6NGPDUGgAQxu3TcA/search?q
uery=work+study
