2.

Method Study
Prepared by Prof. Neepa
Patel

Company
LOGO
 Outline

1. Work Study

2. Method Study

3. Various Charts

August 7, 2018 Prof. Neepa M. Patel, MPSTME 2

 Work Study

 Work Study is a generic term for management services

and system engineering techniques, used to investigate:

 Methods of performing work (Method Study).

 The time taken to do it (Work Measurement).

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 Work Study

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 Work Study (Cont.)

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 Method Study
 Method study is a technique to reduce the work
content mainly by eliminating unnecessary
movements by workers, materials, or equipments.
 However, even after that, there could be substantial
unnecessary time taken for the process because of lack of
management control or inaction of worker.
 Method study is the 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 costs.
 Used to analyze
 Movement of body, people, or material
 Activities of people & machines
August 7, 2018 Prof. Neepa M. Patel, MPSTME 6
 Method Study Objectives

 Improvement of processes and procedures.

 Improvement in the design of plant and equipment.
 Improvement of layout, neat and clean environment and
working conditions.
 Greater job satisfaction, higher standard of safety and
health
 To examine all facts critically
 Improvement in the use of men, materials and machines.
 Economy in human effort and reduction of unnecessary
fatigue.
 Development of better working environment.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 7

 Basic procedure of Method study
Procedure to accomplish method study, called "SREDDIM"
shall be as follow:
1. Select: Select the job or operation that needs
improvement,
2. Record: Record all facts about present method by
direct observations.
3. Examine: examine the job critically and challenge its
purpose, place, sequence and method of performance
by asking; what, why, where, when, who and how
4. Develop: Develop the most practical, efficient and
economical method of manufacture
5. Define : Define the new method.
6. Install: Install the new process as a standard practice
7. Maintain: Maintain the standard practice by check
frequently, match results, correct deviations.
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 Basic procedure of Method study

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 Basic procedure of Method study

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 Basic procedure of Method study

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 Basic procedure of Method study

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 Basic procedure of Method study

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 SELECTION: Factors to be consider

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 Selection: Factors to be consider

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 Basic procedure of Method study
Select
Record

Examine

OK
?

Develop & Define

Install

August 7, 2018
Maintain
Prof. Neepa M. Patel, MPSTME 16
 Recording Technics used in Method Study
Method Study Tools

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 Symbols used in Charts

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 Symbols used in Charts

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 Flow Process Chart Symbols

Operation Delay

Transportation Storage

Inspection

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 Operation

Occurs when an object is intentionally changed in

one or more of its characteristics
Usually occurs at a machine or a work station
Drilling, Painting, Data Entry, Cutting, Sorting, etc.

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 Transportation

Occurs when an object is moved from one place to

another
except when the movement is part of an operation
or an inspection
Using elevator, carrying, moving with material
handling devices

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 Inspection

Occurs when an object is examined for

identification or is compared with a standard as to
quantify or quality
Examine the quantity or quality, read steam gauge
on boiler, detect the defectives

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 Delay
Occurs when the immediate performance or the
next planned action does not take place
Work In Process inventory waiting to be
processed, Employee waiting for an elevator,
Waiting for accumulation of a certain quantity for
packaging

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 Storage

Occurs when an object is kept under control such

that its withdrawal requires authorization
Bulk storage of raw material, finished products
inventory, archived documents

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 Combined Symbols

Two symbols may be combined when two

activities are performed concurrently.

Operation and Inspection

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 Recording Technics used in Method Study
Method Study Tools

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 RECORDING TECHNIQUES –
CHARTS
Micro- Motion charts
SIMO chart
(Therbligs)
Cycle graph
Chronocycle graph
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 Recording Techniques

Macroscopic motion Microscopic motion

Holding a screw driver is an • Reach hand to screw driver
operation in Macro motion chart • Grasp the same
• Then hold that screw driver

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 Recording Techniques
 Charts
1. Operation process chart :
 It is also known as outline process chart. It’s a Bird’s eye
view of whole process of a product.
 An outline process chart is a process chart giving an
over-all picture by recording in sequence only the
main operations and inspections.
 It uses only two symbols : Operation and Inspection
 A brief note of the nature of each operation is made
beside the symbol.

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 Example of Operation Process chart

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 Example of Operation Process chart

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 Recording Techniques
 Charts
2. A flow process chart is a process chart setting out the
sequence of the flow of a product or a procedure by
recording all events under review using the appropriate
process chart symbols.
Flow process chart - Man type
A flow process chart which records what the worker does.
Flow process chart – Material type:
A flow process chart which records what happens to material.
Flow process chart - Equipment type:
A flow process chart which records how the equipment is
used.
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 2. Flow process chart

Flow process chart : Material type

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 Recording Techniques
 Charts
3. Two handed process chart
 It is also known as left hand and right hand process chart.
 In this chart the movements of an operator’s hand are
recorded. It consist two charts, one for the left hand and
other for the right hand.
 Two handed process chart is usually prepared for
repetitive, manual type of operation. In this chart,
operations are recorded in more detail than is done on
flow process chart. The same symbols are used here but
slightly different meaning.
 The inspection symbol is not used. When operator is
inspecting the job it is considered as an operation

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 3.Two Handed Process Chart

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 3.Two Handed Process Chart

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 3.Two Handed Process Chart
Operation/Job : To assemble two
washers and nut to bolt

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 3.Two Handed Process Chart
Operation/Job : To assemble two
washers and nut to bolt

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 3.Two Handed Process Chart

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 Recording Techniques for Method Study

predetermined motion time system (PMTS)

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 4.Multiple Activity Chart
This technique is used to solve problems
where a number of items are dependent on
each other. The aim is to reduce idle times
by using the optimum number of each
item.
Multiple activity charts are the process charts
using a time scale. It usually comes in picture
when work study man wants to record the
activities of one subject with respect to other
on a single chart. Subject may be the worker,
machine or equipment.
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 4.Multiple Activity Chart
It is also known as Gang Process Charts or Man – Machine
Chart
 The worker and machine process chart (Man-machine
chart) is used to study, analyze, and improve one
workstation at a time.
 The chart shows the exact time relationship between the
working cycle of the person and operating cycle of the
machine.
 These facts can lead to utilization of both worker and
machine time, and a better balance of the work cycle.
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 4.Multiple Activity Chart
Types of multiple activity chart
 Man-Machine Activity Chart– When one operator is
working on one machine
 Multi-man Activity Chart– When a group of workers are
working on a machine
 Man- Multi machine activity chart– When a single
operator is working on a number of machines

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 4. Multiple Activity Chart –
Example-1

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 Worker-Machine Chart for a Gourmet Coffee Store

Example-2

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 Worker-Machine Chart for a Gourmet Coffee Store

Example-2

The customer, the clerk, and the coffee grinder (machine) are involved in this
operation. It required 1 minute and 10 seconds for the customer to purchase a
pound of coffee in this particular store. During this time the customer spent 22
seconds, or 31 percent of the time, giving the clerk his order, receiving the ground
coffee, and paying the clerk for it. He was idle during the remaining 69 percent of
the time. The clerk worked 49 seconds, or 70 percent of the time, and was idle 21
seconds, or 30 percent of the time. The coffee grinder was in operation 21
seconds, or 30 percent of the time, and was idle 70 percent of the time.
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 Man-Machine Chart--Example-3

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 Man-Machine Chart--Example-3

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 Man-Machine Chart--Example-3

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 Man-Machine Chart--Example-3

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 Man-Machine Chart--Example-3

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 4. Multiple Activity Chart

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 Principles of Motion Economy

These principles have been developed by

Frank Gilbreth.
There are number of principles concerning
the economy of movements of human body.
There is a possibility for the removal of
unnecessary movements using principles of
motion economy. Then it results in
improvement in productivity.

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 Principles of Motion Economy

These principles may be grouped under three

categories :
1. Use of the human body.
2. Arrangement of the workplace.
3. Design of tools and equipment.

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 1.Use of the human body.

1. The two hands should begin and complete their

movements at the same time.
2. The two hands should not be idle at the same
time except during periods of rest.
3. Motions of the arms should be symmetrical and in
opposite directions and should be made
simultaneously.
4. Movement of body should be such that the work
can be done satisfactorily with minimum labour

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 1.Use of the human body.

5. Momentum should be employed to help the worker, but should

be reduced to a minimum whenever it has to be overcome by
muscular effort.
6. Continuous curved movements are to be preferred to straight-
line motions involving sudden and sharp changes in direction.
7. "Ballistic" (i.e. free-swinging) movements are faster, easier and
more accurate than restricted or controlled movements.
8. Rhythm is essential to the smooth and automatic performance
of a repetitive operation. The work should be arranged to
permit easy and natural rhythm whenever possible.
9. Movement of eyes must be limited to a particular area and it
may not necessary for eyes to change their focus frequently.

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 1.Use of the human body.

Classification of Motion/ Movements :

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 2.Arrangement of Workplace

1. Definite and fixed stations should be provided for

all tools and materials to permit habit formation.
2. Tools and materials should be pre-positioned to
reduce searching.
3. Gravity feed, bins and containers should be used
to deliver the materials as close to the point of
use as possible.
4. Tools, materials and controls should be located
within the maximum working area as shown in
figure and as near to the worker as possible.

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 2.Arrangement of Workplace

5. Materials and tools should be arranged to permit the best

sequence of motions.
6. "Drop deliveries" or ejectors should be used wherever
possible so that the operator does not have to use his hands
to dispose of the finished work.
7. Provision should be made for adequate lighting, and a chair
of the type and height to permit good posture should be
provided. The height of the workplace and seat should be
arranged to allow alternate standing and sitting.
8. To avoid fatigue to worker’s eye ,use contrast colours for
work and work-place.

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 2.Arrangement of Workplace

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 3. Design of Tools and Equipments
1. The hands should be relieved of all work of "holding" the
workpiece where this can be done by a jig, fixture or foot-
operated device.
2. Two or more tools should be combined wherever possible.
3. Where each finger performs some specific movement, as in
typewriting, the load should be distributed in accordance with
the inherent capacities of the fingers.
4. Handles such as those on cranks and large screwdrivers should
be designed so as to permit as much of the surface of the hand
as possible to come into contact with the handle. This is
especially necessary when considerable force has to be used on
the handle.
5. Levers, crossbars and handwheels should be so placed that the
operator can use them with the least change in body position
and the greatest "mechanical advantage".
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 3. Design of Tools and Equipments

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 3. Design of Tools and Equipments

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 Recording Techniques

Micro-motion Study:
Micro motion study technique is best suited for
those operations or activities which are of short
duration and which are repeated hundreds of
time. For example : packaging work
These are the operations or motions which
require very small time and it is quite difficult to
measure time for these motions accurately and the
time required by these motions cannot be
neglected due to repetitive operations.

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 Recording Techniques

Micro-motion Study:
 “Thus micro motion study is the technique of
recording and analysing the timing of basic elements
of an operation with the objective of achieving the best
method of performing the operation.” Such repetitive
short cycle operations involve quick hand movements
which cannot be accurately
 Short cycle operations require to be studied for
microscopic motions e.g., operation of picking up a nut
from bin, grasp nut and move hand back to assembly
position.

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 Recording Techniques

Micro-motion Study:
 Micro motion study is one of the most accurate techniques
of work analysis used for work improvement. It makes use
of motion pictures of the different activities or movement,
with the help of camera. Very small time upto 0.0005
minute can be measured and recorded by this system.
 When picture camera is utilized, the procedure is known as
“MICRO-MOTION STUDY”. The motion time data from the
film is transferred to simo chart. The simo chart data can
be further analyzed for the purpose of work place layout or
method improvement.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 74

 Recording Techniques

Micro-motion Study:
 This technique was developed by Frank Gilbreth who
considered that an operation consists of minute elements
which may be repetitive or non repetitive. He termed these
elements THERBLIG (after his name Gilbreth if spelt bank
word is Therblig).
 Micro-motion study is group of techniques based on the
idea of dividing human activity into division of movements
or group of movements (Therbligs) according to propose
for which they are made.
 Each therbligs has a specific colour, symbol and letter for
recording purposes.

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 Micro-motion Study : Therbligs

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 Classification of Therbligs

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 Steps involved in micro-motion study

1. Filming the operation to be studied

2. Analysing the film data
3. Charting the result of analysis
1) Filming the operation: micro-motion consist of
taking motion picture of activity while being performed
by an operator. The equipment required to make a film
consists movie camera, film strip, wink counter (micro
chronometer) and other usual photographic aids.
*** Wink counter is a timing device which records time in
winks (1 wink = 1/2000 of a minute)(==0.005 mins)

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 Equipment's Required

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 Steps involved in micro-motion study

2,) Analysing the film data: after operation has

been filmed, the film is analysed in the following way:
 Film is run at normal speed so as to get familiar with the
pattern of movement involved.
 A typical work cycle is selected from amongst the final
cycles.
 Film is run at very low speed and is usually stopped or
reversed frequently to identify the motions (Therbligs),
3,)Charting the result of analysis:
 Prepare SIMO chart with this result and then analysis it

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RECORDING TECHNIQUES –CHARTS
Micro- Motion charts
SIMO chart (Therbligs)
Cycle graph
Chronocycle graph

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 2. Simultaneous motion cycle
(SIMO Chart )

Prof. Neepa M. Patel, MPSTME

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 2. Simultaneous motion cycle
(SIMO Chart)

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 Example: place a clamp and nuts in
U-bolt:

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 3.Cycle Graph and Chronocycle graph

Cycle graph and Chronocycle graph were introduced by

Gilbreth. They are photographic methods and are very
accurate and detailed. They are used to trace especially
those movements which are too fast for the human eye to
pursue.

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 3.Cycle Graph

 Another exposure on the some

photographic plate can show
all three aspects
simultaneously i.e. worker,
workplace layout and the path
of movements. Such record is
called cycle graph.

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 3.Cycle Graph

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 4. Chronocycle graph
 Cycle graph neither gives the direction nor the speed of
the movement. This difficulty is overcome by
Chronocycle graph.
 In this system an interrupter is placed in the electric
circuit with the bulb and the light is flashed quickly and
off slowly, then the path of bulb in photograph will
appear as a dotted line with pear-shaped dots indicating
the direction of motions.
 The space between the dots will be according to the
speed of the hand or finger of the body.
 Size and shape of the pear-shaped dot will show
whether body part is in acceleration or retardation .
 The number of dots will give the time taken by the part.
Such a record is called Chrono cycle graph.

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 4. Chronocycle graph

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 Cycle graph and Chronocycle graph

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 5.Flow Diagram
 The flow process chart shows the sequence and nature
of movement but it does not clearly show the path of
movement of men and materials from one place to
another.
 In the path of movements , there are often undesirable
features such as congestion, back tracking and
unnecessary long movements.
 A flow diagram is used to supplement the flow
process chart.it shows the relative position of
productive machinery, storage area and the path
followed by the men or materials is marked on to
flow diagram.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 97

 5.Flow Diagram
 Steps to draw a flow
diagram:
• Draw to scale the plan of work
area
• Mark the relative position of
machine tools, store, racks,
inspection booth etc.
• Draw the actual paths of the
material/worker on the diagram
and indicate the direction of
movement
• Each movement is serially
numbered and show its
direction
• Different colors are used to
identify different types of
movement.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 98

 5.Flow Diagram
 Use of Flow diagram:
• It gives diagrammatical visualization, therefore it is used
with flow process charts to carry out study easily.
• It is used to know whether the material flow in forward
direction or its back tracking is happening.
• It helps to achieve effective plant layout.
• On which station more accumulation of unfinished
product/ material is faced during production and where
they should be arranged that informations are provided
by the flow diagram.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 99

 6.String Diagram
 There are many industrial activities in which the
workers are moving in irregular intervals between a
number of points in a working area , with or without
materials.
 Such as an operator is looking after more than one
machine, on restaurant different persons are serving in
different tables…
 A string diagram is a scale plan or model on which a
thread is used to trace and measure the path of
workers, material or equipment during a specified
sequence of events.
 It gives the clearest picture of what is actually being
done in plant section. In string diagram, movement is
shown by winding a string around the pins inserted at
each work station.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 100

 6.String Diagram

August 7, 2018 Prof. Neepa M. Patel, MPSTME 101

 6.String Diagram
 Steps to draw a flow
diagram:
• A scaled the plan of work
area is first prepared on a
paper and is pinned on
soft board.
• Mark and insert panel
pins at all workstations
between which the
journeys are made. More
pegs/pins may be
stretched in between the
facilities to trace more or
less the actual path
followed by men and
materials.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 102

 6.String Diagram
 Steps to draw a flow
diagram:
• A continuous coloured
unstrechable string, taken from
the first to last warned to trace
the path followed by operators or
materials. Use strings/ threads of
different colours if the movement
of more subjects is being shown
so that their movements are
easily recognized and
distinguished.

• Remove the string to measure

their lengths which
approximately gives distances
travelled by a worker or a
machine or the material.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 103

 6.String Diagram
 Use of String diagram:
• It gives information for removing unnecessary and non-
productive activities.
• More suitable and economical method can be found by
studying this diagram.
• It is also useful to improve plant layout and material
handling methods.
• This diagram is useful to know number of movements of
operator in the plant.
• How much movements of material is there in the plant
can be known from this diagram.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 104

 7.Travel Chart
 It is also known as Cross Chart.

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 7.Travel Chart

Travel Chart: It is a tabular record for presenting

quantitative data about the movement of workers,
materials or equipment between any number of places
over any given period of time.
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 7.Travel Chart

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 7.Travel Chart

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 7.Travel Chart

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 7.Travel Chart

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 Critical Examination

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 Critical Examination

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 Critical Examination

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 Development and Define a new
Method
 Critical examination gives rise to number of creative ideas.
Since all the ideas are not practicable, some of the ideas are
required to be discarded and others are to be refine and
develop.
 Development involves the analysis of the three phases-
evaluation, investigation and selection. For development of the
new method, following approaches can be considered:
1. Eliminate all unnecessary operations
2. Combine operations and elements
3. Change the sequence of operations
4. Simplify the necessary operations.

August 7, 2018 Prof. Neepa M. Patel, MPSTME 120

 Installation of the proposed
Method
 Installation is composed of two steps:
 In the Recommendation phase : the formal written report
should be prepared for the changed method, present the
recommendations to the management. Also provide
information on implementation plan and get the approval of
the management.
 In implementation phase : the entire study effort will go waste
if the proposal is not implemented. Though the responsibility
of implementation is that of top management yet the assistance
of method study man is required to :
1. To tackle problems at implantation phase
2. Minimise delay in implementation process
3. The proposal is implemented in its entirety
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 Maintain the Propose Method

 Method changes does not end up with implementation of

the proposal.
Follow-up after the implementation is equally important. The
maintenance of the proposed method involves:
1. Monitoring and control
2. Audit of the saving
3. Review of the approach
4. Evaluation of effectiveness of proposed method.

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 University questions

August 7, 2018 Prof. Neepa M. Patel, MPSTME 123

 University questions

August 7, 2018 Prof. Neepa M. Patel, MPSTME 124

 University questions

August 7, 2018 Prof. Neepa M. Patel, MPSTME 125

 University questions

August 7, 2018 Prof. Neepa M. Patel, MPSTME 126

 University questions

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 Thank You…..

August 7, 2018 Prof. Neepa M. Patel, MPSTME 128