work study and method study,types of flow process charts

1. Industrial Engineering
UNIT –II
Method study
Prepared By
Prof. Shinde Vishal Vasant
Assistant Professor
Dept. of Mechanical Engg.
NDMVP’S Karmaveer Baburao Thakare
College of Engg. Nashik
Contact No- 8928461713
E mail:- shinde.vishal@kbtcoe.org
Website:- www.vishalshindeblog.wordpress.com
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2. Work Study
• The systematic examination of the method of
carrying on activities so as to improve the
effective use of resources and to set up standards
of performance for the activities being carried out.
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3. • It is a generic term for those techniques, method study
and work measurement which are used in the
examination of human work in all its context. And
which lead systematically to the investigation of all the
factors which affect the efficiency and economy of the
situation being reviewed, in order to effect
improvement
OR
• It is that body of knowledge concerned with the
analysis of the work methods and the equipment used
in performing a job, the design of an optimum work
method and the standardization of proposed work
methods.
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4. Work Study
• Work study has contributed immeasurably to the
search for better method, and the effective utilization
of this management tool has helped in the
accomplishment of higher productivity.
• Work study is a management tool to achieve higher
productivity in any organization whether
manufacturing tangible products or offering services
to its customers.
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5. Work Study
• Method study
• It is the systematic recording & critical examination
of existing and proposed ways of doing work, as a
means of developing and applying easier and more
effective methods and reducing cost
• Work measurement / Time study
• It is the application of techniques designed to
establish the time for a qualified worker to carry out
a specified job at a defined level of performance
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6. Objectives
• To analyze the present method of doing a job,
systematically in order to develop a new and
better method
• To measure the work content of a job by
measuring the time required to do the job for a
qualified worker and hence to establish standard
time.
• To increase the productivity by ensuring the best
possible use of human, machine and material
resources and to achieve best quality product/
service at minimum possible cost
• To improve operational efficiency
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7. Benefits of work study
• Increased productivity and operational efficiency
• Reduced manufacturing costs
• Improved work place layout
• Better manpower planning and capacity planning
• Fair wages to employees
• Better working conditions to employees
• Improved work flow
• Reduced material handling costs
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8. Benefits of work study
• Provides a standard of performance to measure
labour efficiency
• Better industrial relations and employee
morale
• Basis for sound incentive scheme
• Provides better job satisfaction to employees
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9. Scope of work study
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10. Scope of work study
• Method study and work measurement are
closely linked to each other as both are
associated with work study.
• Method study reduces the content of job and
work measurement investigates and reduces
ineffective time associated with job with
establishment of standard time.
• This results into efficient working operations
leading to increase in productivity of that
process
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11. Work Study Procedure
SELECT
RECORD
EXAMINE
DEVELOP
MEASURE
DEFINE
INSTALL
MAINTAIN
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12. Work Study Procedure
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13. INFLUENCE OF METHOD & TIME STUDY IN
PRODUCTION ACIVITIES
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14. Method study
• Systematic recording and critical examination of
existing and proposed ways of doing work, as a
means of developing and applying easier and
more effective methods and reducing cost
• Work methods analysis or method study is a
scientific technique of observing , recording and
critically examining the present method of
performing a task or operation with the aim of
improving the present method and developing a
new and cheaper method.
• It is also known as method improvement or work
improvement.
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15. • Its aim is to find best possible manufacturing procedure
that requires least time and less fatigue to worker.
• Used to analyze
• Movement of body, people, or material
• Activities of people & machines
• Method study is a technique to reduce the work
content mainly by eliminating unnecessary
movements by workers, materials, or equipments.
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16. Objectives of method study
• To study the existing proposed method of doing any
job, operation or activity
• To develop an improved method to improve
productivity and to reduce operating costs
• To reduce excessive material handling or movement
and thereby reduce fatigue to workmen
• To improve utilization of resources
• To eliminate wasteful and inefficient motions
• To standardize work methods or processes, working
conditions , machinery, equipments and tools.
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17. Advantages of method study
• Work simplification
• Improved working method ( cheaper method)
• Better product quality
• Improved work place layout
• Improved equipment design
• Better working conditions
• Better material handling
• Improved work flow
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18. Advantages of method study
• Less fatigue to the operator
• Optimum utilization of all resources
• Higher safety to work men
• Shorter production cycle time
• Higher job satisfaction
• Reduced material consumption and wastages
• Reduced manufacturing cost and higher
productivity
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19. Method Study Procedure
SELECT
RECORD
EXAMINE
DEVELOP
DEFINE
INSTALL
MAINTAIN
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20. • Procedure to accomplish method study, called "SREDIM"
shall be as follow:
• Select: the job or operation that needs improvement,
• Record: all facts, how work is done by chart
methods,
• Examine: every aspect of the job by asking; what,
why, where, when, who and how
• Develop: review ideas, eliminate, simplify, combine,
re-arrange, make new method which more safe, chart
new method, submit for approval,
• Install: the new method, consider best time to
introduce, convince all, train users,
• Maintain: check frequently, match results, correct
deviations.
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21. Method Study ( Steps)
• Select job/process to be examined & observe
current performance
• high process cost, bottlenecks, tortuous route,
low productivity, erratic quality
• Record & document facts
• activities performed
• operators involved - how etc
• equipment and tools used
• materials processed or moved
• Apply critical examination - challenge job
components & necessity (purpose, place, sequence,
method).
• Develop alternative methods & present proposals
• Document as base for new work system
• Install, monitor (slippage) & maintain
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22. Recording techniques
Recording
techniques for
Method Study
Charts
Macro Motion
charts
1.Operations Process Chart
2.Flow Process Chart
3.Two Handed Process Chart
4.Multiplle Activity Chart
Micro Motion
charts
SIMO Chart
Diagrams
1.Flow Diagram
2.String Diagram
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23. Method Study Symbols
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24. Process Chart Symbols
Indicates the main steps in a process, method or procedure.
Usually the part, material or product concerned is modified or
changed during the operation.
2.Inspection
Indicates an inspection for quality and / or check for quantity
1.Operation
3.Transport
Indicates the movement of workers, materials or equipment from place
to place
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25. 4.Temporary Storage or Delay
Indicates a delay in the sequence of events : for example, work waiting
between consecutive operations, or any object laid aside temporarily without
record until required.
5.Permanent Storage
Indicates a controlled storage in which material is received into or issued
from a store under some form of authorization; or an item is retained for
reference purposes.
6.Combined Activities
Indicates a controlled storage in which material is received into or issued
from a store under some form of authorization; or an item is retained for
reference purposes.
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26. E
X
A
P
M
L
E
S
Figure:
Example
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27. Process Charts Used In Method Study
Outline process chart:
An outline process chart records an overall picture of the
process and records only the main events sequence-wise. It
considers only the main operations and inspections.
Operation process chart:
The basic process chart, called an operation process chart, is
understood as a graphic representation of the points at which
the materials are introduced into the process and of the
sequence of inspections and all operations except those
involved in materials handling. It includes information
considered desirable for analysis such as time required to
carry out the operation and the location.
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28. Flow process chart:
Flow process charts are graphic representations of the
sequences of all operations, transportation, inspections, delays,
delays and storages occurring during a process or a procedure
and include information considered for analysis such as, time
required and distance moved.
The flow process chart could be of two types namely,
(i) Flow process chart material or product type.
(ii) Flow process chart machine type or equipment.
Two handed process chart:
In this chart, the activities of a workers’ or operators’ both
hands or limbs are recorded chronographically.
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29. Multiple Activity Chart:
In this chart, the activities of more than one subject worker,
machine or equipment are recorded on a common time scale
to show their inter-relationship.
Flow diagram:
The flow diagram is a drawing or diagram drawn to a scale to
show the relative position of a machine or equipment, jigs and
fixtures, gangways or aisles and shows the path followed by
materials or machines.
String diagram:
It is scale plan or model on which a string or a thread is used
to trace and measure the path of workers, material or
equipments during a specified sequence of events.
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30. SIMO chart:
These indicate the basic motions consisting of three parts,
viz.,
(i) When the motion begins.
(ii) The nature of the motion.
(iii) When the motion ends.
The simultaneous motion cycle chart (SIMO) is a type of
two handed process chart in which the micro motions of
both hands are recorded.
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31. 1.Operation Process Chart
• Also called Outline process chart
• Bird’s eye view of whole process
• Records only major activities and inspections
• Uses only two symbols i.e. operations & inspection
• Constructed by placing symbols one below another
• An operation process chart is a graphic representation of the
sequence of all operations and inspections taking place in a
process.
• Uses:-
• Visualize sequence of operations & inspections in process
• Know where operations selected fits into the entire process
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32. Procedure Followed In Preparing The Chart
1. Write title at the top of the chart.
2. Begin the chart from the right hand side top
corner.
3. Represent the main component at the right
extreme.
4. Represent the sequence of operations and
inspections by their symbols. Connect them by
vertical flow lines.
5. Record the brief description of the activity to the
right side of the symbols.
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33. 6. Note down the time for each activity to the left of the
symbol.
7. Number all operations in one serial order. Start from
the right hand top (from number 1).
8. Similarly number all inspections in another serial
order (starting from 1).
9. Continue numbering, till the entry of the second
component.
10. Show the entry of purchased parts by horizontal
lines.
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34. Operation Process / Outline Process Chart:
example : manufacture of electric motor
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36. Outline Process Chart For Plywood Manufacture
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37. Flow Process Chart
• A flow process chart is a graphical representation of
the sequence of all the activities (operation,
inspection, transport, delay and storage) taking
place in a process.
• It is the detail version of outline process chart
recording all the event.
• Process chart symbols are used here to represent the
activities.
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38. Guidelines For Making A Flow Process Chart
1. The details must be obtained by direct observation—charts must
not be based on memory.
2. All the facts must be correctly recorded.
3. No assumptions should be made.
4. Make it easy for future reference.
5. All charts must have the following details:
(a) Name of the product, material or equipment that is observed.
(b) Starting point and ending point.
(c) The location where the activities take place.
(d) The chart reference number, sheet number and number of
total sheets.
(e) Key to the symbols used must be stated.
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39. Type of flow process charts
1. Man/ Worker type flow process chart
This flow process chart records what the worker does.
2. Material type flow process chart
This flow process chart records how the material is
handled or treated.
3. Equipment type flow process chart
This flow process chart records how the equipment or
machine is used.
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40. Standard formats used for flow process chart
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41. Example: Collection of materials from store (Man Type)
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43. Machine/ Equipment
Flow Process Chart:
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44. Two-Handed Process Chart (or) Right Hand,
Left Hand Chart
• It is the process chart in which the activities of two
hands of the operator are recorded.
• Motions of both hands of worker are Right hand-Left
hand chart recorded independently.
• It shows whether the two hands of the operator are
idle or moving in relation to one another, in a
timescale.
• It is generally used for repetitive operations.
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45. Two-Handed Process Chart (or) Right Hand,
Left Hand Chart
• Operation: Represents the activities grasp, position, use, release
etc. of a tool, component or material.
• Transport: Represents the movement of the hand or limb to or
from the work or a tool or material.
• Delay: Refers to the time when the hand or limb is idle.
• Storage (Hold): The term ‘hold’ is used here instead of storage.
This refers to the time when the work is held by hand.
• The activity ‘inspection’ by hand is considered as an operation.
Hence, the symbol for inspection is not used in this chart.
• Two-handed process chart can be used for assembly, machining
and clerical jobs.
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46. • The objective of this investigation is to eliminate or
reduce the unwanted motions and to arrange the
remaining motions in a best sequence.
• A two-handed process chart is made up of two columns in
which the activities of the left hand and right hand and the
appropriate symbols are respectively recorded in
sequence.
 The activities of the two hands are inter-related by
aligning the symbols on the chart so that movements
by both hands appear opposite to each other.
 Additional columns can be designed to record the
activities of the other parts of the body whenever
necessary.
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48. LEFT HAND RIGHT HAND
Hold Letter
Reach for pen
Grasp pen
Carry pen to
paper
Sign letter
Return pen to
holder
Release pen in
holder
Move hand back
to letter
Task:- Signing a letter
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50. •A Chart in which the activities of more than one item are
recorded on a common time scale to show their inter-
relationship.
•Man machine chart is the type of multiple activity charts.
•TYPES:
• Man - Machine chart: One man handling one job or
one machine.
• Man - Multi machine chart: One man handling a
numbers of machines.
• Machine Multi - man chart: A group or gang doing
collectively one job as in riveting.
• Multi – Man - Machine chart: A number of persons
working on a computer system.
Multiple activity chart
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51. Multiple Activity Chart
• In it, the activities of more than one item, worker,
machine or equipment are recorded on a common time
scale to show their inter relation ship.
• It is used when a worker operates a number of machines
at a time. It is also used when a number of workers jointly
do a job.
Why:
Multiple Activity Charts are very useful tool for understanding
the flow of work in a cyclic process and as a consequence
understanding which resource is controlling the overall progress of
the work.
The tool can be used to model different scenarios to determine the
optimum mix of resources for the work.
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52. Purpose of Multiple Activity Chart
• To detect the idle time on machine and workers
• To optimize work distribution between workers
and machines.
• To decide no. of workers in a group.
• To balance the work team
• To examine the activities.
• It is used for recording the complex movements
of material or men.
• Used to find out the most economical route.
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53. Application Of Multiple Activity Chart
• Plant repair & maintenance.
• Job construction.
• Planning team work.
• It is used to check whether the work
station is correctly located.
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54. Time Operator Machine 1
Washer
Machine 2
Dryer
# Sec Load clothes & detergent in
machine 1
Being loaded Idle
idle Run Idle
- Remove clothes from machine 1 Being unloaded Idle
- Load clothes into machine 2 Idle Being loaded
- Load clothes & detergent into
machine 1
Being loaded Run
- Idle Run Run
- Remove clothes from machine 2 Idle Being unloaded
- Hang clothes Idle Idle
Multiple activity chart for doing three loads of laundry
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56. Micro Motion Study
• Suggested by Frank Gilbreth.
• Technique for recording and timing an activity.
• Divides human activities in a group of movements or micro
motions (called therblings).
•Helps to find best pattern of movements for an operator that
consumes less time and requires less effort.
Steps involved
• Filming the operation to be studied.
• Analysis of the data from the film.
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57. Use of films in micro motion study
Main advantages of films over visual methods are:
• Permit greater detailing than eye observation
• Provide greater accuracy than pencil, paper and stop
watch
• More convenient
• Provide a positive record
• Help in the development of the work study person.
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58. • Based on the idea that human activity can be divided
into movements or group of movements (therbligs)
according to the purpose for which they are made.
• The therbligs cover movements or reasons for the
absence of movement.
• Each therblig has specific color, symbol and letter for
recording purposes.
• Therbligs refer primarily to motions of the human body
at the workplace and to the mental activities associated
with them.
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59. 2. Movie Camera.
EQUIPMENT REQUIRED
1. 16 mm film.
3. wink counter.
Exposure meter. Motion picture projector with screen
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60. • It is dealing with the:
• Movement of man who is working, not
machine
• Study of micro motion of body parts and hands
• Gilbreth describe 18 motions known as
therblig.
Therblig-Gilbreth Chart
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62. Micro-motion Study
Therbligs
 Search (SH) – attempt to find an object using eyes or hand
 Find (F) – mental reaction at end of search
Select (ST) – choose among several objects in a group
 Grasp (G) – grasp an object
 Hold (H) – hold an object
Transport loaded (TL) – move an object with hand and arm
Transport empty (TE) – reach for an object
 Position (P) – position object in defined location
Assemble (A) – join two parts
 Use (U) – manipulate a tool
Disassemble (DA) – separate multiple parts that were previously joined
 Inspect (I) – determine quality of object
Pre-position (PP) – position object for next operation
Release load (RL) – release control of an object
Unavoidable delay (UD) – waiting due to factors beyond worker control
Avoidable delay (AD) – worker waiting
Plan (PN) – decide on an action
Rest (R) – resting to overcome fatigue
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64. SIMO CHART
• “SIMO” stands for simultaneous-Motion Cycle chart. It is
one of micro motion study devised by Gilbreth
• It presents graphically the separable steps of each pertinent
limb of the operator under study.
• It is an extremely detailed left and right hand operation
chart.
• It records simultaneously the different therbligs performed
by different parts of the body of one more operators on a
common time scale.
• The movements are recorded against time measured in
“Winks” (1 wink= 1/2000 minute).
• These are recorded by a “Wink Counter” positioned in such
a location that it can be seen rotating during filming
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66. 66
SIMO chart format:
(SImultaneous MOtion cycle chart)
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67. Recording Techniques - Diagrams
67
Indicates the path of movement
Study of traffic & frequency over different routes of
plant
Identification of back-tracking & obstacles during
movements
Study of different layout plans & select optimal
layout
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68. Flow Diagram
1)Layout of w/p is drawn to scale
2)Relative positions of m/c tools, work benches, etc
are marked
3)Path followed by the subject under study is traced
by drawing lines
4)Each movement is serially numbered and
indicated by arrow for direction
5)Different colors are used to denote different types
of movements
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69. A flow diagram is essentially a flow process chart drawn to:
1. Show the layout of a facility.
2. Show the flow of work through that area
3. Show overcrowding areas, crossing worker paths, total
travel.
4. Identify how layout can be redesigned to reduce travel,
motion, collisions, etc.
5. Store materials near where they are used.
6. Increase efficiency and safety.
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70. 70
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71. String Diagram
71
String/Thread is used to measure the distance
Records the pattern of movement of a worker
working within a limited area during a certain
period of time
Repetitive movements can be conveniently
traced
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72. String Diagram
1)Layout of the w/p or factory is drawn to scale on a soft board
2)Pins are fixed into boards to mark the location of work
stations,
3)Pins are also driven at the turning point of the routes
4)A measured length of thread is taken to trace the movement
(path)
5)The distance covered by the object is obtained by measuring
the remaining part of the thread and subtracting it from the
original length
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73. Applications
1) It is used for recording the complex movements of
material or men.
2)Back tracking, congestion, bottlenecks, under
utilized paths are easily found out.
3)It is used to check whether the work station is
correctly located.
4)Used to record irregular movements.
5) Used to find out the most economical route
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76. Value engineering and Value analysis
• Value analysis originated from second world war due
to the shortage of essential material.
• Lawrence D Miles was the first to develop the
technique and name it.
• Value Analysis is one of the major techniques of cost
reduction and control. It is a disciplined approach
which ensures the necessary functions for the
minimum cost without diminishing quality, reliability,
performance and appearance.
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77. • According to Society of American Value Engineers
(SAVE) “Value analysis is the systematic application
of recognized techniques which identify the function
of a product or services establish a monetary value
for the function and provide the necessary function
reliability at that lowest overall cost.”
• Value analysis is an organized approach to identify
unnecessary costs associated with any product,
material, part, component, system or service by
analysis of function and efficiently eliminating them
without impairing the quality functional reliability or
its capacity to give service.
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78. • In the field of value investigation, value refers to
economic value, which itself can be sub-divided into four
types as cost value, exchange value, use value and esteem
value.
• “Cost Value” is the measure of sum of all costs incurred
in producing the product. The ‘cost value’, therefore is the
sum of raw-material cost, labour cost, tool cost and
overheads expended to produce the product.
• “Exchange Value” is the measure of all the properties,
qualities and features of the product which make the
product possible of being traded for another product or
for money.
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79. • “Use Value” is the measure of properties, qualities
and features which make the product accomplish a
use, work or service.
• “Esteem Value” is the measure of properties, features,
attractiveness graphic packaging and the like which
increases sales appeal or which attracts customers and
create in them a strong desire to own the product.
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80. 17/01/2017 PROF.V.V.SHINDE NDMVP'S KBTCOE NASHIK 80

81. Value Engineering
• Value Engineering (VE) is defined as an organized effort
directed at analyzing the functions of systems, equipment,
facilities, services, and supplies for the purpose of achieving
the essential functions at the lowest life-cycle cost
consistent with required performance, quality, reliability
and safety.
• Value engineering (VE) is systematic method to improve
the "value" of goods or products and services by using an
examination of function.
• Value Engineering is an organizational creative approach
for the purpose of identifying of unnecessary cost.
• Unnecessary cost are that which provides neither quality,
nor use, not appearance, not life and customer features
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82. When is VE used ?
• Value Engineering is used to determine the best
design alternatives for Projects, Processes, Products,
or Services
• Value Engineering is used to reduce cost on existing
Projects, Processes, Products, or Services.
• Value Engineering is used to improve quality,
increase reliability and availability, and customer
satisfaction .
• Value Engineering is also used to improve
organizational performance.
• Value Engineering is a powerful tool used to identify
problems and develop recommended solutions.
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83. Six steps in value engineering
Information
Phase
Creativity
Phase
Evaluation
Phase
Planning
Phase
Reporting
Phase
Implementation
Phase
Clearly identify the problem(s) to be solved, and gather
information on the background, functions and
requirements of the product, process, or system.
Brainstorm ideas on how to improve the high cost,
broken, or inadequately performed key functions.
Screen ideas for acceptance, score remaining ideas on
a scale and group ideas into categories. Develop
design scenarios, and selection criteria. Rate and rank
ideas.
Plan how to sell ideas to management, identify key
recommendations, plan management presentation.
Give oral presentation to management, or develop
written report.
Get management approval, make management plan,
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84. 17/01/2017 PROF.V.V.SHINDE NDMVP'S KBTCOE NASHIK 84