Industrial Engineering

Work Study
Dr. Kumar Abhishek

Assistant Professor
Department of Mechanical
Engineering
IITRAM
 Work Study
• Since the beginning of human race there had always been a tendency to improve in many

activities, but it has been recognized at a very later stage.

• Work study is one of the most important management techniques which is employed to

improve the activities in the production.

• British Standard Glossary (BSG) defines, “Work study is a generic term for those

techniques, particularly method study and work measurement, which are used in the

examination of human work in all its contexts, 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.”

 Cont.…. Work Study
 Work study is simply the study of work. It is the analysis of work into smaller parts

followed by rearrangement of these parts to give the same effectiveness at a better

cost.

 Work study is used to associate two sets of techniques which are distinct

approaches but yet interdependent.

1. Method Study

2. Work measurement
Work Study in a diagrammatic manner

Work Measurement:
 Method Study
 British Standard Glossary (BSG) defines, “Method study is the systematic recording

and critical examination of existing and proposed ways of doing work, as a mean of

developing and applying easier and more effective methods and reducing costs.”

 Method study is concerned with “the way in which work is done (i.e. method)”. It is

used to simplify the way to accomplish a work and to improve the method of

production.
 Cont.…. Method Study
 Method Study aims to determine the most effective method of performing a job, the

most logical layout of manufacturing facilities, the smooth flow of men and

materials throughout the organization and the right placement of inspection stages

to enable processing of a job through the smallest possible time and the least

possible cost.

 There is a continuous need for analyzing existing method even if they are

developed to be most efficient and effective because best method today may not

be the best method after some period. Subsequent investigations may reveal that

more economical material is available, more efficient machines, tools, jigs, fixtures

have been designed, better inspection methods have been evolved, more
 Method Study - Purpose & Benefits
Purpose/Benefits of method study

 To evolve creatively and innovatively improvement in processes and procedures.

 To determine the correct sequence of operations and avoid duplication (if any).

 To improve layout, smoothen material flow, reduce backtracking and avoid obstacles.

 To reduce unoccupied time of the operator and thereby obtain effective use of human efforts.

 To improve utilization of the equipment and thereby reduce manufacturing cycle time per piece.

 To select material of right specifications, cut down process waste, reduce defectives, and

thereby reduce raw material consumption per unit of production.

 To achieve economy in human effort and reduction of unnecessary fatigue.

 To develop a better physical working environment.

 Method Study - Procedure
Procedure of method study

1. Select - A specific job will be chosen to be examined.

2. Record - The current performance of the job is observed, facts are recorded and

documented. The important features taken into consideration are:

 Activities performed

 Operators involved

 Equipment and tools used

 Materials processed or moved

Cont.…. Method Study - Procedure
3. Examine - The job is then examined and its components are challenged on their

feasibility and necessity (purpose, place, sequence, method).

4. Develop - After this alternative methods are developed, documented and the most

suitable will be selected, becoming the base for the new Work Instructions.

5. Install - The new method is installed as standard practice and the operators will be

trained on those new Work Instructions.

6. Maintain - Control procedures to measure the performance, as well as preventing

drifting back to previous methods of work will also be introduced.

 Work Study - Benefits
 It helps in optimum use of plant,  It helps in the evaluation of human work.

equipment, manpower and material.  It helps in efforts towards productivity

 It helps in establishing the standard of improvement.

performance.  It helps in the elimination of wasteful efforts,

 It helps in developing standard work useless material handling, etc.

methods.  It helps in job simplification and work

 It helps in establishing the most efficient standardization.

and effective utilization of human effort.  It is helpful in developing plant safety

 It helps in synchronizing various resources schemes, equipment utilization, plant layout

like men and machine. and conductive work environment.

Method Study -
Procedure Selection of the Job
Selection of the jobs to be studied for methods improvement by the method study
practitioner is a managerial responsibility and it (selection) may be based on economic,
technical or human consideration.

1.Economic consideration:- It justifies selection based on economic worth (i.e. money

saving potential of the job.
2.Technical consideration:- It identifies jobs which require studies to overcome
manufacturing difficulties (excessive rejection, relaxation in prefixed performance
standards, inability of the shops to stick to specified machining parameter such as
speeds, feeds, depth of cut etc., inconsistent quality etc.)
3.Human consideration:- It is usually given weightage while introducing method study
practices for the first time.
Method Study -
Procedure Recording of Facts
 Recording by long hand (descriptive method) has its limitations, it is not
recommended for use in method study. Instead, five symbols and eight charting
conventions are used to record facts relating to the job under study.
Method Study Symbols

1. Operation 3. Transport

2. Inspection 4. Delay

5. Storage
 Recording of Facts- Method Study
Method Study -
Procedure Symbols
 Operation:-
An operation occurs when there is a distinct change in physical or chemical
characteristic of an object or, when there is an addition or subtraction or,
when there is consumption of physical effort or, when information is given
or received. An operation is represented by a circle.

 Inspection:-
An inspection occurs when the object is verified against predetermined
standards of quality or quantity, or both. Inspection, unlike operation,
does not take the object one step forward towards completion. It merely
verifies whether or not the object has undergone the required operation
as per specifications. Inspection is represented by square.
 Recording of Facts- Method Study
Method Study - Cont.….
Procedure Symbols
 Transport:-
An transport occurs when the object is moved from one place to
another. Example- Movement of materials or trolley. Transport is
represented by an arrow.
 Delay:-
A delay occurs when the object is held up resulting in delay in the start
of next event i.e. next operation, inspection or transport. Delay is
represented by a letter D.
 Storage:-
A storage occurs when the object is kept in an authorized custody and is
protected against unauthorized removal. Storage is represented by an
inverted triangle.
 Recording of Facts: Recording
Method Study -
Procedure
Methods

Information Recording Techniques:

 Different methods of information recording for the existing method are

 Charts
 Diagrams
 Templates and Models
 Photographic aids (Micromotion study)
 Graphic Techniques (cyclegraph and choronocyclegraph)
Method Study -
Procedure
Recording of Facts:-Recording Methods:-Charts

 Charts:
Charts are the most popular method of recording data. The activities comprising the job
are recorded by means of symbols and charting conventions
Method Study - Cont.….
Procedure
Recording of Facts:-Recording Methods:-Charts
The different type of charts are.

 Operation Process Chart: to give a bird’s eye view of entire process.

 Flow Process Chart:

 Man type (or operator process chart): Show detailed sequence of activities
performed by the workman.
 Material type (or product process chart): Show detailed sequence of activities
performed on the materials.
 Equipment type: Show detailed sequence of activities performed by the
equipment.
Method Study - Cont.….
Procedure
Recording of Facts:-Recording Methods:-Charts

 Multiple Activity Chart: to study man machine utilization, determine number of

machines to be manned by an operator and the like.

 Two Handed Process Chart (Operator Chart): to study work bench layout.

 Travel Chart: Study the movement of materials, men or equipment.

 Process Chart
 A Process Chart is a graphic means of representing the activities that occur during a
manufacturing or servicing job.

 There are several types of process charts. These can be divided into two groups.

1. Those which are used to record a process sequence (i.e. series of events in the order
in which they occur) but do not depict the events to time scale. Charts falling in this
group are

 Operation process chart

 Flow process chart – (man / material / equipment type)
 Operator chart (also called Two Handed Process Chart)
Cont.….
Process Chart

2. Those which record events in the sequence in which they occur on a time scale so

that the interaction of related events can be more easily studied. Charts falling in

this group are

 Multiple activity chart

 Simo chart
 Operation Process Chart
 An operation process chart provides the chronological sequence of all operations

and inspections that occur in a manufacturing or business process.

 An operation process chart gives the detailed step by step account of what is done

to the materials from beginning of the first stage to the last (finished product

stage).

 Only operations and inspections performed on the material are depicted on this

chart & transports, delays and storages are not included.

 The operation process chart can be compared to a map of a city where one can have

a fair idea of the layout of the city from its map but one cannot know from it about

the lanes and by-lanes & their inhabitants.

 Flow Process Chart
 A flow process chart sets out the sequence of flow of work of a product, or any part of

it through the section or the department or the factory by recording the events under

review.

 It is prepared in a manner similar to that of operation chart except that in addition to

symbols for ‘operation’ and ‘inspection’, symbols for ‘transport’, ‘delay’ and storage

are also shown.

 Separate flow process charts are prepared for components of the assembly (usually

one flow process chart is prepared for each major component of he assembly) . This

implies that the operation process chart is normally in multiple lines while flow process

chart is usually in a single line.

Cont.…. Flow Process Chart

 Flow process charts are of three types: product or material type (also known as

product process chart) which shows the events that occur to material, the operator

or man type (also known as operator process chart) that depicts the activities

performed by the man, & the equipment type which exhibits the activities

performed by the equipment.

 An important and valuable feature of this chart is its recording of non-productive

hidden costs, such as delays, temporary storages, unnecessary inspections, and

unnecessary long distances traveled. When the time spent on these non productive

activities is highlighted, analyst can take steps to minimize it and thus reduce costs.
 Two Handed Process Chart
Two Handed Process Chart :

 It is also called Left Hand – Right Hand chart or Operator Process Chart and shows
the activities of hands of the operator while performing a task.

 It uses four elements of hand work: Operation, Delay (Wait), Move and Hold.

 Its main advantage lies in highlighting un-productive elements such as

unnecessary delay and hold so that analyst can take measures to eliminate or
shorten them.
 Multiple Activity Chart
 A multiple activity chart is chart on which the activities or more than one subject are

recorded to indicate their inter-relationship in a given cycle.

 Worker-Machine process chart and gang process chart fall in the category of multiple activity

charts.

 A worker-machine chart is used for recording and analyzing the working relationship between

operator and machine on which he works. It is drawn to time scale. Analysis of the chart can

help in better utilization of both worker and machine time. The possibility of one worker

attending more than one machine is also sought from the use of this chart.

 A gang process chart is similar to worker-machine chart, and is used when several workers

operate one machine. The chart helps in exploring the possibility of reducing both the
 Simo Chart

Simo Chart:

 A Simo chart is another Left-Hand Right-Hand chart with the difference that it is

drawn to time scale and in terms of basic motions called therbligs. It is used when

the work cycle is highly repetitive and of very short duration.

 Diagrams
Diagrams:

 Every business activity requires movement of men and materials form one
location to another. Every movement is not essential & some of them may be
avoided by rearrangement of the facilities within the department or by changing
the sequence of activities.

 Operation process chart indicate the sequence of events but do not show
movements while flow process charts do record movements but they do not
provide a visual picture. The problems concerning movements can be better
visualized by drawing a diagram which may be either a flow diagram or string
diagram.
Cont.…. Diagrams

 A diagram gives pictorial view of the layout of workplace or floor on which locations

of different equipment, machines, etc. are indicated. The movement of subject (man

or material) is then indicated on the diagram by a line or a string. The diagrams are

valuable in highlighting the movement so that analyst can take steps to simplify or

reduce it and thus effect saving in time or reduction in collisions / accidents.

 Two types of diagrams are common: Flow diagram and string diagram.
 Flow Diagrams
 Flow diagrams are the scale plans on which the movements of an object are traced by

lines.

 It shows the relative position of the machine tools, work benches, storage racks,

inspection benches etc. on a scaled diagram on which are marked the paths followed

by the workmen and materials.

 String Diagrams
 String diagrams are the scale plans on which the movements of an object are traced

by means of a string. Its advantage over flow diagram is that repetitive movements

between work stations which are difficult to be traced on a flow diagrams can be

conveniently shown on string diagram.

 Templates and 3-D models
• Two-dimensional cut outs made from thin card sheet representing machinery, furniture,
etc. can be used for developing new layouts and methods. The templates may have
pieces of permanent magnet attached to them, so that when used on iron board; they
remain glued on the board whenever placed.

• A scaled 3-D model of a working area helps easy understanding of lighting, ventilation,
maintenance and safety aspects that may be important in a method. Such models are
often of great value in demonstrating the advantages of the proposed changes to all
concerned. However, their use is limited because of higher cost involved. Some computer
softwares are available which help in constructing the layout and possibility of visualizing
the working of process in a systematic way.
 Work Measurement
• British Standard Glossary (BSG) defines, “Work measurement is the application of
techniques designed to establish the time for a qualified worker to carry out a specific
job at a defined level of performance.”

• Work Measurement is a term which covers several different ways of finding out how
long a job or part of a job should take to complete.

• WM is the means of measuring the time taken in the performance of an operation or

series of operations in such a way that the ineffective time is shown up and can be
separated out.

• WM is also used to set standard times to carry out the work, so that any ineffective time
is not included later.
 Work Measurement - Purpose & Benefits
Purpose of Work Measurement
• To reveal the nature and extent of ineffective time, from whatever cause so that
action can be taken to eliminate it.
• To set standard time for various operations.
• For determining idle or rest time of operator.
• Rate operator performance.
• Gain information to calculate overall production capabilities and Data for capacity
planning.

Benefits of method study

• Knowledge about Standard Times is gained
• Ability to estimate total work content
• Operators can be appraised on factual grounds
 Work Measurement - Techniques
Techniques of Work Measurement

• Time study - The study with the stop watch.

• Work sampling - It helps to figure out the amount of time occupied by different activities
associated with men or machines.
• Analytical Estimating
• Synthesis from standard data - It is the compilation of known elements which have been
observed by the stop watch studies.
• Predetermined Motion Time Systems (P.M.T.S.) - The time required to do a job is
synthesized by combining the predetermined times for different elements of the job.

The first two techniques involve direct observations whereas the rest are data based and
analytical in nature.
 Work Measurement - Procedure
Procedure of Work Measurement

1. Select: The work to be studied and determine the objectives of the study.
2. Record: All the relevant data relating to circumstances in which the work is being
done.
3. Examine: The recorded data and the detailed breakdown to ensure the most
effective methods and motions are being used and unproductive elements are
separated from productive elements.
4. Measure: The time required to complete each element using appropriate work
measurement techniques and calculate the time required to com pile the work cycle
which is known as basic time.
5. Compile: The standard time for the operation or work cycle.
6. Define: Precisely the series of activities and method of operation for which the time
has been compiled and issue the time standards for the activities and methods
 Time & Motion Study
• A time and motion study is used to reduce the number of motions in performing a task in
order to increase productivity & to make sure that the job being evaluated does not
include any unnecessary motion by the worker.
• Manufacturing engineering students are being prepared to design work stations, develop
efficient and effective work methods, establish time standards, estimate labor costs,
develop effective tooling, and layout manufacturing facilities. However, the most
important thing is to learn how to train production workers in these skills and techniques
so they can become motion and time conscious.
• Motion study is for cost reduction, and time study is for cost control. Motion study is the
creative activity of motion and time study.
• Motion study is design, while time study is measurement.
• Frederick W. Taylor and his followers developed and refined the Time Study & Frank
B. Gilbreth and his wife Lillian developed and refined the Motion Study.
• Earlier the two studies are discussed individually, today they generally are
discussed as one.
• The objective of the Time and Motion Study is to determine a ‘normal’ or average
time for a job, by using observers to record exactly how much time is being
devoted to each task.
 Time Study
• International Labor Organization (ILO) defines, “Time study is a work measurement technique for
recording the time and rate of working for the elements of a specified job, carried out under specified
condition & for analyzing the data so as to obtain the time necessary for carrying out the job at a
defined level of performance.”
• A method created to determine the ‘correct time’ it takes to complete a certain task
• A method to establish ‘the one best way to perform a task’
• Time study can reduce cost significantly well.
• In organizations that operate without time standards, 60% performance is typical & when time
standards are set, performance improves to an average of 85%. This is a 42% increase in performance:
85% - 60%
------------------ = 42% performance increase.
60%
OT
OT: time taken to complete
a particular task
NT PRF: a procedure in which
time study engineer
compares the performance
ST
of operators under
observation to the normal
performance and
determines a factor called
rating factor
NT: also called base time
or leveled time is the time
that trained workers need
to complete the task at a
normal pace
Assuming that the total observed time for an
operation of assembling an electric switch is 1.00
min. If the rating is 120%, find normal time. If an
allowance of 10% is allowed for the operation,
determine the standard time.
 Time Study - Equipments
The equipments to be used in Time study are

• Stop Watch
• Fly-back type
• Non Fly-back type
• Split hand stop watch

• Time Study board

• Time Study forms

• A small calculator

• A reliable clock with seconds hands

• Measuring instruments such as measuring tape, steel rule, micrometer, spring balance
etc.
 Time Study - Procedure
• Select the job to be timed
• Standardize the method
• Select the operator
• Record details
• Break the task into elements.
• Measure the duration of each element and assess the pace of performance
(Performance rating)
• Determine representative time for each element
• Extend observed time into normal time
• Assess relaxation and other allowances
• Compute the standard time of job
 Motion Study
• Motion studies are performed to eliminate waste. Before any improvement in quality or
quantity of output, any study of operations time, any scheduling of work or balancing of
workload or any calculation of standard time, a study of the current and proposed method is
required.

• Motion study comes first before the setting of time standards. Motion study is a detailed
analysis of the work method in an effort to improve it.

• Studies of overall factory flow or process, called macromotion studies, and then additional
studies of detail or operations, called micromotion studies, should be completed for a
project.
 Macromotion Study

• Any process can be studied by dividing it into process activity. Although each activity is
different, depending on the product, there are five classes of activities that are included in
all processes. Savings, may be found in the process by reorganizing activities.

• These activities found in every sequence of processes are

• Operations Changes in the properties of the product
• Transportations Changes in the location of the product
• Inspection Confirmation that change fits to specification
• Delay Wait for start of operation, transportation, or inspection
• Storage Wait until needed
• When the process is first studied, each activity is recorded and arranged into one of the
five classes. All observed activities are recorded, and activities not done are not
recorded. The purpose of each activity should be studied.

• Example: Pick up the screw driver may have its timed value of several seconds and is
studied under macromotion study.
 Macromotion Study Contd…
• Typically, the questions Who? What? Where? When? Why? and How? must be answered.

• Next, each event is observed in the following sequence:

• Can the activity be eliminated? If not,

• Can the activity be combined and done with another activity? If not,
• Can the activity be rearranged so occur in the sequence at an easier
time? If not.
• Can the activity be simplified with shorter distances, mechanical assist,
or reduced complexity?
• Once these questions are asked and the improvement sequence is defined, it is
necessary to draw a chart or diagram that shows the motion improvements.

• Process Flow Plan A plan-view plant layout with activities

overlaid
• Process Operations Chart The sequence of serial and parallel
operations
• Process Chart All serial activities on a preprinted form
• Flow Process Chart All serial and parallel activities on a
single page
• Work Cell Load Chart A plan view with repetitive operations
• Route Sheet A planning tool for scheduling operations
 Micromotion Study
• Considerable wasted motion and idle time can occur within an
operation. This time can’t be found with macromotion studies
because is usually within one process operation. The improvement
is gained from reducing the operation cycle time.
 Contd… Micromotion Study
• Applicable for operations with very short cycles which are repeated thousands of
times.
• Goes into greater details to determine where movements and efforts can be saved and
to develop the best possible patterns of movements.
• Enables operators to perform the operation repeatedly with minimum effort and
fatigue.
• The technique used for this typically involves filming the operation and hence is known
as micromotion study.
• Examples of operators studied could be cashier in the bank – routine job of taking
payment slips from customer and issuing cash.
 Time Standard
• The definition of a time standard is “the time required to produce a product at a work
station with the following three conditions:

(1) a qualified, well-trained operator,

(2) working at a normal pace,
(3) doing a specific task.”

• The importance of time standards can be shown by the three statistics 60%, 85%, and
120% performance.
• The time standard is one of the most important pieces of information produced in the
manufacturing department. It is used to develop answers for the following problems:

• Determining the number of machine tools to buy

• Determining the number of production people to employ
• Determining manufacturing costs and selling prices
• Scheduling the machines, operations, and people to do the job and deliver on
time
• Determining the assembly line balance, determining the conveyor belt speed,
loading the work cells with the correct amount of work, and balancing the work
cells
• Paying incentive wages for outstanding team or individual performance
• Evaluating cost reduction ideas and picking the most economical method based
on cost analysis, not opinion
•
Example of Time Standard
How Many Machines Do We Need?
• One of the first questions rose when setting up a new operation or starting
production on a new product is “how many machines do we need?” The answer
depends on two pieces of information:
• How many pieces do we need to manufacture per shift?
• How much time does it take to make one part? (Time standard)
EXAMPLE
• The marketing department wants us to make 2,000 wagons per 8-hour shift.
• It takes us 0.400 minutes to form the wagon body on a press.
• There are 480 minutes per shift (8 hours/shift x 60 minutes/hr).
• 50 minutes downtime per shift (breaks, clean-up, etc.)
• There are 430 minutes per shift available @ 100%.
• @ 75% performance (based on history) (0.75 x 430 = 322.5).
• There are 322.5 effective minutes left to produce 2,000 units.
322.5
---------------- = 0.161 minutes per unit, or 6.21 parts per
minute.
2,000 units
 Example of Time Standard Contd…
EXAMPLE

• The 0.161 minutes per unit is plant rate. Every operation in the plant must produce
a part every 0.161 minutes; therefore, how many machines do we need for this
operation?

Time standard = 0.400 minutes/unit

----------------------------------------------------- = 2.48 machines
Plant rate = 0.161 minutes/unit

• This operation requires 2.48 machines. If other operations are required for this kind
of machine, we would add all the machine requirements together and round up to
the next whole number.

• In this example, we would buy three machines. (Never round down on your own. You
 Work Sampling
Work Sampling

• According to BS 3138:1969 “A technique in which statistically competent number of instantaneous

observations are taken, over a period of time, of a group of machines, process or workers. Each
observation records what is seen to happen and the percentage of observations recorded for a
particular activity or delay is a measure of the percentage of time absorbed by the occurrence.”

• Work sampling is a sampling technique wherein a large number of observations are conducted at
random intervals of time and the state of each member of the group-working or not working is studied.
• The observations of non-working are further amplified and the cause of delay is recorded. The data so
collected can be utilized in a variety of ways.
 Work Sampling - Advantages
Advantages of work sampling

• Cost reduction and cost control.

• Assessment of allowances for output standards.
• Fixation of output standards.
• Testing the accuracy of the output standards.
 P.M.T.S.
Predetermined Motion Time System

• According to BS 3138:1969 “Predetermined motion time system (PMTS) is a work

measurement technique whereby times established for basic human motions are used
to build up the time for a job at a defined level of performance.”

Technique of PMTS

• The technique to build PMTS data does not measure element time by a stop watch
and thus it avoids the inaccuracies being introduced owing to the element of human
judgment.
• It is assumed that all manual tasks in industries are made up of certain basic human
movements (like reach, move, disengage etc.) which are common to almost all jobs.
• The average time taken by the normal industrial workers to perform a basic
 Contd… P.M.T.S.
Steps involved in collecting PMTS data

• Select large number of workers doing varieties of jobs under normal working
conditions in industries.
• Record the job operations on a movie film (micromotion study).
• Analyze the film, note down the time taken to complete each element and compile
the data in the form of a table or chart.

• The jobs selected are such that they involve most of the common basic motions and
are worked under different set of conditions by workers having different ages and
other characteristics.
• Once the table for various basic motions are ready, the normal time for any new job
can be determined by breaking the job into its basic movements, noting time for each
motion from the tables and adding up the time values for all the basic motions