Direct time study problems

Solved problems about Direct time

study problems
Release: 2022-04-22

Contenido
Nomenclature ...................................................................................................................................... 2
Problem statement nº1. Direct Time Study ......................................................................................... 3
Solution Problem nº1 ...................................................................................................................... 4
Problem nº2. Direct Time Study ......................................................................................................... 6
Solution Problem nº2 ...................................................................................................................... 7
Problem nº3. Direct Time Study ....................................................................................................... 10
Solution problem nº3 ..................................................................................................................... 12

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 1/14
Direct time study problems
Nomenclature

Tef: Effective working time

Tn: Normal time
Tobs: Observed time
MP: Tasks while machine is off
MM: Tasks while machine is on
PD: Process delay
Af: Fatigue allowance (% value)
FAT: Fatigue allowance time
Ap: Personal needs allowance (% value)
PAT: Personal needs allowance time
Apfd: Allowance for fatigue, personal and delay (% value)
Tm: Machine cycle time
Tstd: Standard Time (Work Standard)

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 2/14
Direct time study problems
Problem statement nº1. Direct Time Study
You want to calculate the standard time (Tstd) at a workstation where a machine and an operator
are located. As the current Time & Methods Engineer cannot devote much time to this, he will be
in charge of doing only a partial direct timing using a stopwatch and the person in charge of the
section will sample 2,400 observations.
Two cyclic work elements (to be measured) have been identified (Element A & Element B), one
waiting element (C measured by work sampling) and one manual acyclic work element (D to be
measured by sampling and by direct timing).
• Element A has been defined as a manual work element carried out while the machine is off.
It consists of removing the finished part from the machine, placing a new one in the machine
and turning the machine on again.
• Element B is a manual work element too. While the machine is processing the new part, the
worker has to grease the part extracted during Element A in the previous cycle.
• Element C consists of waiting for the machine to finish its automatic cycle.
• Element D is a manual work element that is performed for every two parts manufactured.
It consists of filling the container of grease that is used in Element B. During the observation,
it has been observed that the operator does it after work element B. Nevertheless, in the
approved work method, it is clearly stipulated that it must always be carried out after
Element C.

Below are the results of a brief direct time study that has been considered sufficient for the level
of accuracy that is sought. Measured times are expressed in thousandths of a minute:
Element A Element B
Cycle Performance Rating Tobs Performance Rating Tobs
1 90 140 120 380*
2 105 120 80 140
3 95 132 90 125
4 95 490* 100 113
* The acyclic work element D was carried out during a cyclic work element.

In the sampling, it was observed that the performance rate of element D was 90.

During this study, 90 parts were produced, and the following observations of elements C and D
were obtained:
Element C Element D
Number of observations of the 1,100 500
element

Calculate:
a) Normal times of elements A and B (Tn[A], Tn[B])
b) Normal time of element D (Tn[D])
c) Normal time of element C (Tn[C])
d) Time granted as a Fatigue Allowance (FAT)
e) Time granted as Personal needs Allowance (PAT)
f) Standard time (Tstd)
Consider a fatigue allowance of 7% and a personal needs allowance of 5%.

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 3/14
Direct time study problems
Solution Problem nº1
To calculate the normal times of the cyclic elements, the valid cycles of the study of times are
used. We assume that:
- min-3 = thousands of minutes
- during one cycle, just one part is produced.

Question a) Normal times of elements A and B

Element A Element B
Rating Tobs Tn Rating Tobs Tn
90 140 126 80 140 112
105 120 126 90 125 112,5
95 132 125.4 100 113 113
Average 125.8 Average 112,25

Tn[B] = 125,8 min-3 Tn[B] = 112,25 min-3

Question b) Normal time of element D

To calculate the normal time of element D, we use the time values when they happened:
(𝑃𝑅𝐴,𝑐𝑦𝑐𝑙𝑒4 ∙𝑇𝑜𝑏𝑠 [𝐴𝑐𝑦𝑐𝑙𝑒4 ]−Tn[A])+(𝑃𝑅𝐵,𝑐𝑦𝑐𝑙𝑒1 ∙𝑇𝑜𝑏𝑠 [𝐵𝑐𝑦𝑐𝑙𝑒1 ]−Tn[B])
𝑇𝑛 [𝐷 ] 𝑒𝑎𝑐ℎ 2 𝑐𝑦𝑐𝑙𝑒𝑠 = ( )=
2
95 120
(100∙−125.8)+(100∙380−112,5) 339.7+343.5
( )=( )=341.6 min-3
2 2
Since the frequency is 1 every 2 cycles, the normal time of element D to consider per cycle is:
Tn[D] = 341.6 / 2 = 170.86 min-3

Question c) Normal time of element C

To calculate the waiting time C, it is necessary to use the work sampling study. However, we do
not have all the data as you can see below:
The percentage (%) of appearance of element C is: %C = 𝑝𝐶 = 1,100/2,400 = 0.4583=45.83%
𝑝 ∙𝑇𝑇
The time would be: T[C] = 𝐶 =0.4583*TT/90
𝑄𝐶
Where TT is the duration of the study in which the 90 parts were produced.
As TT is a waiting time from the operator perspective, it is considered as a Process Delay.
T cannot be rated. T is not a normal time since it is considered a special supplement/allowance
due to process delay.
In order to calculate T, the result of the work sampling study of the already calculated element D
will be used.
We know that its % of occurrence is: %D =𝑝𝐷 = 500/2,400 = 0.21 = 20.83%
𝑝 ∙𝑇𝑇
The normal time would be Tn[D]= 𝑃𝑅 ∙ 𝑇𝑜𝑏𝑠 = 𝑃𝑅 ∙ 𝐷 =90/100*0.21*T/90= 170.86 min-3
𝑄𝐷
and clearing T = 81,333.3 min-3 = 1.37 hours
Tn[C] = 0.46*81,333.3/90= 417.66 min-3

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 4/14
Direct time study problems

Fig. 1 Scheme of the cycle

Fig. 2 Scheme of an average cycle

Question d) Time granted as a fatigue allowance (FAT)

Elements A, B and D are working elements. Therefore, a fatigue allowance (Af) should be assigned
for them.
FAT = Af (Tn[A]+ Tn[B]+ Tn[D]) = 0.07 * (125.8 + 112.5 + 170.8) = 28.62 min-3

Question e) Time granted as a personal need allowance (PAT)

The personal needs allowance (Ap) to take into account for both work elements and process delays
is:
PAT = Ap (Tn[A]+ Tn[B]+ Tn[D] + Tn[C]) = 0.05 * (125.8 + 112.25 + 170.86 + 415.66) = 41.33 min-3

Question f) Standard time (Tstd)

As the waiting time of the operator is less than half a minute per cycle, the allowance cannot be
reduced. FAT and PAT are added without reduction.
The standard time (Tstd) would be:
Tstd = Tn[A]+ Tn[B]+ Tn[D] + Tn[C] + FAT + PAT = 125.8 + 112.25 + 170.8 + 415.7 + 28.64 + 41.24 =
896.53 = 0.896 man-min / part

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 5/14
Direct time study problems
Problem nº2. Direct Time Study
In Workstation #04 of the manufacturing and assembly line of fans "Fan Deck Metallic", the gluing
of the parts of the housing and other operations are carried out.
An operator is currently assigned to the tasks performed there. The operator works with an
automatic ultrasonic gluing press. Two manual work elements have been identified:
• Element AAA: consists of extracting the elaborated part from the press, placing a new one
in the press and turning the press on.
• Element BBB: consists of placing a wire in the part elaborated during the previous Element
AAA. The work method indicates that it must be done while the press processes a new part.

A CCC element has also been identified. It consists of waiting for the press to end its automatic
cycle.
Every 20 parts, the operator performs the DDD element. This consists of fetching a new bag of 20
wires. The method indicates that this acyclic element must be done within the machine cycle time.
Nevertheless, in some cases, the operator does it when he wants.
In order to re-balance the line, it has been decided to perform a new direct time study of the
operations that are carried out in the production system.
The results of the direct time study (using a stopwatch) are as follows:
AAA Element BBB Element CCC Element
Cycle PR Time PR Time PR Time
1 90 122 80 115 - 120
2 105 105 105 519* - **
3 95 116 100 85 - 150
4 100 110 100 87 - 148
5 100 560* 90 94 - 141
* The acyclic element DDD has been detected
** No waiting time for the operator has been detected since the machine had stopped before BBB
element finished.

The measured times are in thousandths of a minute (min-3) and PR = Performance Rating. Consider
a basic fatigue allowance of 7% and a personal needs allowance of 5%.
You must calculate:
1. Normal time of the cyclic elements (Tn[AAA + BBB])
2. Normal time of the acyclic element (Tn[DDD])
3. Machine cycle time (Tm)
4. Fatigue allowance time (FAT)
5. Personal allowance time (PAT)
6. Standard time (Tstd)

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 6/14
Direct time study problems
Solution Problem nº2
Question 1) Normal time of the cyclic elements (Tn[AAA + BBB])
Manual Element AAA
Valid Cycle Rating Obs. Time Norm Time (Tn)
1 90 122 109,8
2 105 105 110,25
3 95 116 110,2
4 100 110 110

Average Tn[BBB] = 110,06 min-3

Manual Element BBB

Valid Cycle Rating Obs. Time Norm Time (Tn)
1 80 115 92
3 100 85 85
4 100 87 87
5 90 94 84,6

Average Tn[BBB] = 87,15 min-3

-3
Tn[AAA+BBB] = 197,21 min

Question 2) Normal time of the acyclic element (Tn[DDD])

Manual acyclic DDD element:
• 1st observed data (560-110) = 450 min-3
• 2nd observed data (519∙1.05-89) = 456 min-3
• Tn[DDD] each 20 cycles = (450 + 456) / 2 = 453 min-3

The frequency of this element, based on objective data, is 1 per 20 cycles. The normal time for
Element DDD to be considered per cycle will be:
• Tn[DDD] = 453/20 = 22.65 min-3

Question 3) Machine cycle time (Tm)

To determine the machine cycle time, the study should be limited to the cycles where a process
delay has been detected (cycles 1, 3, 4 and 5).
In these cycles, the observed machine cycle time is then the sum of the manual work element
times when the machine was processing a part and the measured process delay.

By observing the man-machine diagram of the operation below, we can calculate the Time
Machine (Tm) as follows:
• Tm = 115 + 120 = 85 + 150 = 87 + 148 = 94 + 141
• Tm = 235 min-3

Question 4) Fatigue allowance time (FAT)

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 7/14
Direct time study problems

Fig. 3 Man-machine diagram of 20 work cycles

According to the standard work method, the acyclic element DDD must be carried out during the
process delay.
As can be seen in Fig. 3, the total normal time is greater than the difference between TM and
Element BBB (work element performed while machine is running). We know that when the worker
performs the acyclic element DDD, there will be no process delay and the machine will wait for the
operator to return.
• Tm-Tn[BBB] = 235-87 = 148 <453

That is to say that

• Once every 20 cycles, the real duration of the cycle is:
o Tn[AAA] + Tn[BBB] + Tn[DDD] = 197 + 453 = 650 min-3
• For the remaining 19 cycles, the real duration of the cycle is:
o Tn[AAA] + Tm = 110 + 235 = 345 min-3
In short, as the time of work element DDD is greater than 148, part of the acyclic element DDD is
carried out during the machine cycle and part is carried out after the end of the machine cycle.

To determine the “average cycle”, we should average the activity while the machine is on as well
as while the machine is off.

Part of the acyclic work element DDD must be included while the machine is running and should
be calculated as follows:
• Element DDD during Tm : 148/20 = 7.4 min-3

Let’s assume that Machine Preparation (MP) tasks are performed with the machine off. In this
case, part of the acyclic work element DDD must be included while the machine is off and should
be calculated as follows:
• Element DDD during MP = (453-148) / 20 = 305/20 = 15.25 min-3

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 8/14
Direct time study problems
Consequently, the normal cycle time is
• Tn[AAA]+ Tm + Element DDD during MP = 110 + 235 + 15.25 = 360.25 ≅ 360 min-3

Assuming that DP is the Delay of the automated Process (Time in which the worker is idle
waiting for the machine to finish its automated process). The process delay (DP) can be
calculated as follows:
• DP = Tm - Tn[BBB]- Element DDD during Tm =235-89-7,4 = 138.6 ≅ 139 min-3

The fatigue allowance is calculated considering all manual work elements (in this case: AAA, BBB
and DDD).
Since the process delay PD = 0,139 min is less than 0,5 min, the entire fatigue allowance (FAT)
must be added to the normal cycle time.
• FAT = 0,07 (197 + 22.65) = 15,37 ≅ 15
• FAT = 15 min-3

Question 5) Personal allowance time (PAT)

The personal needs allowance (PAT) is calculated considering all work elements that make up the
entire normal cycle time. In this case, the following elements should be considered: Element AAA+
Tm + Element DDD during MP.
Since the process delay PD = 0,139 min is less than 10 min, the personal needs allowance time
(PAT) must be added to the normal cycle time.
• PAT = 0.05 x 360 = 18
• PAT = 18 min-3

Question 6) Standard time (Tstd)

Consequently, the Standard Time (also called Work Standard) will be as follows:
• Tstd = Tn + FAT + PAT = 360 + 15 + 18 = 393 man-min-3/part = 0.393 man-min-3/part

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 9/14
Direct time study problems
Problem nº3. Direct Time Study
In a company that manufactures metal parts, there are two workstations in series. Workstation 1
(WS1) is a numerical control machine. Workstation 2 (WS2) is a manual finishing station.

WS1: Workstation of the Numerical Control Machine

At WS1, the operator loads and unloads the machine that carries out a forming process. While the
machine is on, the operator should fetch parts located in a container which holds around 100
parts. The time it takes the operator to fetch the parts is unknown. Usually, this is considered a
process delay (PD).

The working day is 8 hours long. Traditionally, a break of half an hour is given to eat and rest.

To estimate this process delay, you have carried out a work sampling during 4 work periods of 3
hours each. During the observations, the operator was performing 3 main types of activity: (1)
feeding the machine while the machine is off, (2) fetching parts and (3) waiting for the machine to
finish its automatic cycle (process delay).
Of the 240 observations made, you observed:
- in 47 observations, the operator was feeding the machine with the machine was off,
- in 94 observations, the operator was fetching parts,
- in 94 observations, the operator was waiting for the machine to finish its automatic cycle
and
- in another 5 observations, the operator was performing personal needs.

During the duration of the working sampling study, 879 parts had been produced.
The top management considers that an additional allowance factor for personal time and fatigue
of 2.3% must be applied to the entire duration of the worker's time spent at the workplace.

WS2: Manual Finishing Station

After WS1, each metal part arrives at WS2. There, an operator performs a series of manual work
activities. As an example, the operator adds two components to the metal part.
To estimate the standard time at WS2, a direct time study was performed using a stopwatch.
The work cycle of the operator has been divided into 2 work elements (element 1 and element 2).
The results of the study are shown in the table (times are expressed in thousandths of a minute).
Note that, during the study, 2 acyclic work elements were noted and must be considered when
determining the standard time.

Element 1 Element 2
Cycle PR Tobs PR Tobs
1 90 460 100 1,762**
2 100 1,910** 90 345
3 110 1,680* 90 355
4 120 350 90 1,690*
5 100 410 120 255
* Element that consists of fetching a container which contains 100 parts.
** Element that consists of checking the previous parts produced. This is carried out once every 30
produced parts.

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 10/14
Direct time study problems
You must:
• At WS1:
1. Determine the normal time of the activity of the operator while the machine is off
1. Determine the normal time of replenishment work.
2. Define the Standard time (Tstd) at this workstation.
3. If, on a given workday, 900 parts have been produced, calculate the average work
performance rate (base 100) of the operator.

• At WS2:
1. Calculate the standard time at this workstation, applying a fatigue allowance of 10%.
2. If, on a given workday, 525 parts have been produced, calculate the average work
performance rate of the operator.

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 11/14
Direct time study problems
Solution problem nº3
WS1: Numerical control machine Workstation
Question 1) Normal time of the activity of the operator while the machine is off (PD)
Effective minutes of the operator's work:
• Tef = (8.00-0.50) × 60 = 450 man-min / day

If during 450 man-min, 879 parts have been produced, the standard time (Tstd) is then:
• Tstd = 450/879 = 0.512 man-min / part

The personal needs and fatigue allowance (2.3%) should be applied as follows:
• Tstd = MP + MM + FAT + PAT = (MP + MM + PD) × (1+ Apfd)
= (MP + MM + PD) × 1.023 = 0.512 man-min / part
• MP + MM + PD = 0.500 min

In this case, we will assume that

2. MP is while the operator works while the machine is off
3. MM is when the operator is performing replenishment activities
4. PD is when the operator is waiting for the end of the machine automatic cycle
5. PN is personal needs

Using the work sampling study, we can then calculate the percentage of time of each activity type:
• % MP = 47/240 = 19.6%
• % PD = 94/240 = 39.2%
• % MM = 94/240 = 39.2%
• % PN = 5/240 = 2.1%

%PN is useful to be sure that personal needs allowance granted is sufficient.

The duration of the study is:
• 4 periods × 3 hours × 60 min / h = 720 min

As Tstd has been calculated considering a normal performance rate, the production level should
have been:
• 720 / 0.512 = 1,406 parts

Consequently:
• 𝑀P = 720 × 0.196 / 1,406 = 0.100 min
• PD = 720 × 0.392 / 1,406 = 0.201 min

Question 2) Normal time of the replenishment work

The normal time of the replenishment work element is the time it takes for the operator to fetch
100 parts placed in a specific container. This acyclic work element is performed while the machine
is on, and therefore will be:
• Tn[MM] each 100 cycles = 0.201x100 = 20.1 min
• Tn[MM] = 720 × 0.392 / 1,406 = 0.201 min

Question 3) Standard time at WS1

So, we can estimate Tm:
• Tm = 𝑀𝑀 + 𝑃D = 0.402
• Tstd = 0.512 man-min / part

Tm cannot be changed at the operator's will, so it remains constant whatever the worker
performance rate is.

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 12/14
Direct time study problems
Question 4) Average work performance rate of the operator
If 900 parts are produced on a given day, the time to produce 1 part is:
• 7.5 × 60/900 = 0.5 man-min / part

This time includes two main activities:

- The time of MP performed by the operator (adjusted to its work performance rate) plus the
time of Tm with its corresponding allowances. This occurs 99 cycles out of every 100.
1.023 × (MP+ Tm) × 99/100
- The time of MP performed by the operator (adjusted to its work performance rate) plus the
time of MM with its corresponding allowances. This occurs once every 100 cycles.
1.023 × (MP + MM) × 1/100
1.023 × [99/100× (MP+ Tm) + 1/100× (MP + MM)] = 0.5 [Exact case]
1.023 × (MP + Tm) = 1.023 × (MP + 0.402) = 0.5 [Approximation]
Using the approximation, MP = 0.087
As Tobs×PRObs = Tn×100
The observed performance rate (PRobs) can be calculated as follows:
• 0.087×PRObs = 0.1×100
• PRobs = 114.94 = 115

WS2: Manual finishing workstation

Cycle PR Tn[Element 1] PR Tn[Element 2]

1 90 414 100 1,762**

2 100 1,910** 90 311
3 110 1,848* 90 319
4 120 420 90 1,521*
5 100 410 120 306

The average normal time of the two elements should be calculated not taking into account the
elements marked with * and **. The results are as follow:
• Tn[1] ≈ 0.415 • Tn[2] = 0.312
Element 1 Element 2
Cycle Rating Tobs Tn Cycle Rating Tobs Tn
1 90 460 414 2 90 311 279,9
4 120 350 420 3 90 319 287,1
5 100 410 410 5 120 306 367,2
Average Tn 414,67 Average Tn 311,40

The normal time of the acyclic element A (𝑇𝑛 [𝐴]) should consider the capacity of the box and the
number of metallic parts consumed per cycle. As a box holds 100 parts and 2 parts are consumed
per cycle, 𝑇𝑛 [𝐴] is calculated as follows:
𝑇𝑛 [𝐴]
1 (𝑃𝑅1,𝑐𝑦𝑙𝑒3 × 𝑇𝑜𝑏𝑠,𝑐𝑦𝑐𝑙𝑒3 [1] − 𝑇𝑛 [1]) + (𝑃𝑅2,𝑐𝑦𝑙𝑒4 × 𝑇𝑜𝑏𝑠,𝑐𝑦𝑐𝑙𝑒4 [2] − 𝑇𝑛 [2])
= ( )
𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 2
110 90
2 (100 × 1,848 − 0.415) + (100 × 1,521 − 0.312)
𝑇𝑛 [𝐴] = ( ) = 0.027
100 2

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 13/14
Direct time study problems

The normal time of the acyclic element B (𝑇𝑛 [𝐵]) can be calculated following the same logic (once
every 30 produced parts):
100 90
1 (100 × 1,910 − 0.415) + (100 × 1,752 − 0.312)
𝑇𝑛 [𝐵] = ( ) = 0.049
30 2

The total normal time is then

• Tn = Tn[1] + Tn[2] + Tn[A] + Tn[B]
= 0.415 + 0.312 + 0.026 + 0.049
= 0.802 min / part
And the standard time will be
• Tstd = 1.1 × 0.802 = 0.882 man-min / part

As in 7.5 hours, 525 parts have been produced, the standard time is
• Tstd [obs] = 7.5 × 60/525 = 0.85 man-min / part

Therefore, since it is a manual work activity in this workstation,

• PRobs = 0.88/0.85×100=103.5~104

Julien Maheut http://hdl.handle.net/10251/181033

ROGLE – UPV 14/14