Unit - 1

Chapter - 2

Work Study
 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.”
• 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:
 Work Study - Benefits

• It helps in optimum use of plant, equipment, manpower and material.

• It helps in establishing the standard of performance.
• It helps in developing standard work methods.
• It helps in establishing the most efficient and effective utilization of human effort.
• It helps in synchronizing various resources like men and machine.
• It helps in the evaluation of human work.
• It helps in efforts towards productivity improvement
• It helps in the elimination of wasteful efforts, useless material handling, etc.
• It helps in job simplification and work standardization.
• It is helpful in developing plant safety schemes, equipment utilization, plant layout and
conductive work environment.
 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.
• 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 satisfactory material handling equipments can now be
procured and so on.
 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

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.
 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
 Method Study - Procedure
Recording of Facts
Method Study Symbols

1. 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.

2. 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.

3. 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.
 Method Study - Procedure
Recording of Facts
Method Study Symbols

4. 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.

5. 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.
 Method Study - Procedure
Recording of Facts
Recording 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. 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.
• 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.
(i) 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)

(ii) 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

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

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.
• 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.
 Multiple Activity Chart

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
operator time and idle machine time.
 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.
 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.