METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

METHOD STUDY
Comprehensive Reference Guide
with Methods Engineer Job Description

INDUSTRIAL ENGINEERING | WORK STUDY | LEAN MANUFACTURING

The systematic approach to improving work methods, reducing waste,

and optimising human effort across manufacturing operations.

Prepared: 13 May 2026

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

1. Definition & Overview

Method Study is the systematic recording and critical examination of existing and proposed ways of
doing work, with the aim of developing and applying easier, more effective methods and reducing costs.
It forms one half of Work Study, the other being Work Measurement.

Core Objective Primary Focus Expected Outcome

Improve work methods and Analyse motion, time, and flow of Reduced cost, improved quality &
procedures work safety

2. Objectives of Method Study

Process & Procedure Objectives Human & Environmental Objectives

• Improve processes and procedures • Reduce unnecessary human effort and

• Optimise plant and equipment design fatigue
• Improve facility layout and material flow • Improve workplace ergonomics and posture
• Reduce material handling distances • Enhance worker safety and reduce injury
• Maximise machine utilisation rates • Improve morale and working conditions
• Ensure a comfortable physical environment

3. The SREDIM Procedure

Method Study follows a structured 6-step cyclical procedure called SREDIM. Each step must be
completed rigorously before proceeding to the next.

▼ SREDIM PROCEDURE — STEP-BY-STEP FLOWCHART ▼

S Choose the work to study — based on economic (high cost, bottleneck), technical
(poor quality, breakdowns), or human (safety, fatigue, morale) factors.
SELECT

R Gather all relevant data using process charts, flow diagrams, string diagrams,
and direct observation notes.
RECORD

Critically examine every recorded activity using the Primary Questioning

E Technique: What? Where? When? Who? How? — followed by Why? and What else?

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

EXAMINE

D Design the most practical, economic, and effective method using ECRS (Eliminate,
Combine, Rearrange, Simplify) and motion economy principles.
DEVELOP

Implement the new method: train operators, update SOPs, rearrange

I workstations, and obtain management approval. Document as the standard
INSTALL method.

M Monitor the installed method through audits and performance reviews. Ensure
reversion to old methods is prevented. Update when conditions change.
MAINTAIN

4. Recording Techniques & Diagrams

Recording uses standardised charts and diagrams. The correct technique is selected based on work type,
the subject being studied (man, material, or machine), and the level of detail needed.

4.1 ASME Standard Process Chart Symbols

Symbol Activity Description

Something is created, changed, assembled or disassembled — the

○ OPERATION
primary value-adding step.
Material, person, or object is moved from one location to
→ TRANSPORT
another. Not adding value — a target for reduction.
Checked for quality, quantity, or correctness against a defined
□ INSPECTION
standard. Does not change the item.
Unplanned or uncontrolled waiting. The item or person awaits
D DELAY
the next activity. Always targeted for elimination.
Deliberate, authorised holding of material — raw, WIP, or
▽ STORAGE
finished goods awaiting planned issue.

4.2 Types of Process Charts

Chart Type Best Used For Key Characteristic

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

Outline Process Chart High-level process overview Uses only ○ Operations and □
Inspections
Flow Process Chart (Man) Individual worker activity All 5 ASME symbols; person is the
sequence subject
Flow Process Chart Tracking a component through All 5 symbols; material/component is
(Material) the process the subject
Two-Handed Process Chart Detailed manual assembly or Records left and right hand actions
bench work simultaneously
Multiple Activity Chart Worker–machine or multi- All subjects on a common time-scale
worker interaction bar chart
SIMO Chart Micro-motion analysis of hand Uses Therblig elements from filmed
movements analysis

4.3 Diagrams Used in Method Study

Diagram Purpose Application Example

Flow Diagram Traces movement paths on a scaled Identifying excessive transport in a

plan of the work area factory layout
String Diagram Uses physical thread to measure Analysing a stores operative's daily
total travel distance movement
Travel Chart (From–To) Quantifies movement volumes Input to layout planning and
between all departments department sequencing
Cyclegraph Photographs light-traces of Repetitive short-cycle assembly
hand/body movement paths operations
Chronocyclegraph Records movement timing via light Speed analysis in micro-motion
flashing frequency study
Spaghetti Diagram Visual map of actual VSM companion for identifying
product/operator flow (Lean tool) waste walks

4.4 Flow Diagram — Layout Schematic (Conceptual)

FLOW DIAGRAM — SCHEMATIC REPRESENTATION

A Flow Diagram is drawn to scale on a plan of the work area. ASME symbols are placed at
their physical locations, and directional arrows trace the path of movement between
activities.

○ OPERATION → TRANSPORT □ INSPECTION ▽ STORAGE

Marked at workstation Shown as directional Marked at inspection point Marked at storage area
arrow

Key analysis principle: Overlapping or crossing movement paths on the diagram indicate poor
facility layout. Excessive transport distances and D-shaped Delay symbols are primary ECRS
targets.

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

5. Critical Examination — The Questioning Technique

Every recorded activity is subjected to structured questioning. This is the most analytically demanding
phase of Method Study and directly feeds the ECRS improvement action.

5.1 Primary and Secondary Questions

Dimension Primary Question Why? Secondary → ECRS Action

PURPOSE What is done? Why is it done? What else could be done? →

ELIMINATE

PLACE Where is it done? Why there? Where else could it be done? →

REARRANGE

SEQUENCE When is it done? Why then? When else could it be done? →

REARRANGE

PERSON Who does it? Why that person? Who else could do it? →
COMBINE / SIMPLIFY

MEANS How is it done? Why that way? How else could it be done? →
SIMPLIFY

5.2 The ECRS Improvement Hierarchy

ECRS must be applied in strict priority order. Eliminating an activity is always better than simplifying it.

Priority Action Meaning Practical Example

ELIMINATE Remove the activity entirely — no Remove an intermediate WIP

1st resource used, maximum benefit storage area; supply direct to
line
COMBINE Merge two or more activities to Combine drilling and deburring
2nd
reduce steps and handling into one machine operation

REARRANGE Change the sequence of operations Move final inspection to

3rd
to improve flow or reduce transport immediately before packaging

SIMPLIFY Make the remaining activity easier, Introduce a jig to eliminate

4th quicker, and less effortful manual alignment time on
assembly

6. Principles of Motion Economy

Motion economy principles guide the design of the improved method. Their goal is to minimise wasted
human movement, reduce physical load, and create a productive, ergonomic work environment.

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

A. Use of the Human Body

• Both hands should start and finish movements simultaneously

• Neither hand should be idle except during rest periods
• Motions should be symmetrical and made simultaneously about the body centreline
• Smooth curved motions are preferred over sharp directional changes
• Ballistic (free-swinging) movements are faster than restricted motions — use momentum
• Use the lowest classification of hand/arm movement sufficient for the task
• Continuous curved movements preferred over zig-zag paths

B. Arrangement of the Workplace

• Fixed, designated locations for all tools and materials — always in the same place
• Tools and materials pre-positioned within the normal work area (elbow-radius zone)
• Gravity-feed bins and drop delivery slots to minimise hand travel distance
• Good lighting at appropriate level and angle — eliminate glare and shadows
• Work surface height and seat height suited to the task and the worker anthropometry
• Adequate space for components, tools, and finished parts without clutter
• Materials delivered to and removed from point of use — not central stores

C. Design of Tools and Equipment

• Use jigs and fixtures to eliminate holding the workpiece by hand

• Combine tools wherever possible (e.g. multi-function hand tool)
• Pre-position tools in spring-loaded holders at the exact point of use
• Use foot pedals or knee levers to free both hands for productive work
• Levers, handwheels, and controls positioned for maximum mechanical advantage
• Tool handles designed to contact the largest possible area of the hand — reduce grip force
• Controls and displays arranged to match human sensory and motor capabilities

7. Relationship to Lean & Other IE Tools

Tool / Technique Connection to Method Study Typical Application

Value Stream Mapping VSM is a macro-level method study — Map end-to-end production flow to
(VSM) applies the same logic at system identify waste categories
level
5S Methodology 5S implements motion economy and Sort, Set in order, Shine,
workplace arrangement principles Standardise, Sustain the workplace
Kaizen Events Kaizen workshops apply SREDIM 2–5 day events targeting a specific
logic for rapid, focused improvement process or cell
SMED (Single Minute Separates internal/external Reduce setup times below 10
Exchange of Die) elements — a targeted method study minutes

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

on changeover
Work Measurement Method Study defines the method; Time study, MOST, or MTM applied
Work Measurement sets the after method is defined
standard time
Ergonomics / Human Method Study drives ergonomic RULA, REBA assessments to
Factors workstation design and risk complement motion economy
reduction
Poka-Yoke (Error Simplify step of ECRS leads to error Jigs, templates, and limit switches
Proofing) -proofing as a design outcome prevent mistakes

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

JOB DESCRIPTION

Methods Engineer
Industrial Engineering / Manufacturing Operations

Job Title Methods Engineer

Department Industrial Engineering / Manufacturing Engineering / Operations
Reports To IE Manager / Plant Manager / Head of Manufacturing
Location Manufacturing Site / Production Facility
Employment Type Full-time, Permanent
Experience Level Mid-level (3–7 years in manufacturing / IE environment)

ROLE SUMMARY

The Methods Engineer is responsible for analysing, designing, and implementing optimised
manufacturing and operational processes using Industrial Engineering tools. This role
applies Method Study, Work Measurement, Lean methodologies, and ergonomic principles to
improve productivity, quality, and working conditions across the production environment.

The postholder works closely with Production, Quality, Maintenance, and R&D teams to
ensure that every operation is performed in the safest, most efficient, and most cost-
effective way possible — using a rigorous, evidence-based approach.

Key Responsibilities

Core Engineering Duties Continuous Improvement & Project Work

• Conduct full method studies using SREDIM • Lead Kaizen events and rapid improvement
on all manufacturing processes workshops
• Create and maintain flow process charts, • Apply VSM to identify and eliminate the 8
flow diagrams, and string diagrams wastes
• Perform time studies and establish • Support 5S implementation and sustain
standard times using MOST / MTM workplace organisation
• Design improved workstation layouts • Drive SMED projects to reduce changeover
applying motion economy principles time
• Develop and maintain Standard Operating • Collaborate on new product introduction
Procedures (SOPs) and work instructions (NPI) process design
• Calculate labour efficiency, utilisation, and • Conduct capacity planning and line
OEE metrics balancing studies
• Evaluate ergonomic risk using RULA, REBA, • Provide ROI analysis to support capital
or NIOSH equations investment justification
• Maintain the Methods and Time (M&T) • Mentor supervisors and operators in IE
database tools and Lean thinking

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

Required Qualifications & Skills

Requirement Detail

Education BSc / MSc in Industrial Engineering, Mechanical Engineering,

Manufacturing Engineering, or equivalent
Experience 3–5 years in a manufacturing or production environment in an IE,
methods, or process engineering role
Method Study Proficiency in flow process charting, ECRS analysis, flow diagrams, and
motion economy application
Work Measurement Time study, predetermined motion systems (MOST, MTM-1/2), and
standard time setting
Lean / Six Sigma Lean practitioner certificate preferred; Green Belt or Black Belt an
advantage
CAD / Layout AutoCAD, SolidWorks, or FactoryCAD for facility and workstation
layout design
Data Analysis Advanced Excel; Minitab or equivalent for statistical process analysis
and control charts
ERP / Software SAP, MES systems, and optionally process simulation tools (Tecnomatix,
Arena, FlexSim)
Communication Strong written and verbal skills; able to present findings to both shop
floor teams and senior management

Key Performance Indicators (KPIs)

Productivity & Efficiency Metrics Quality, Safety & Delivery Metrics

• Labour efficiency improvement (%) • Ergonomic risk score reduction

• OEE improvement on target production (RULA/REBA)
lines • Reduction in reportable work-related
• Standard time accuracy vs. actual cycle injuries
time • SOP compliance rate on the shop floor
• Changeover time reduction achieved (SMED • First-pass yield on new products launched
%) • On-time delivery of IE project milestones
• Annual Kaizen savings delivered (€)

Competencies & Personal Attributes

Analytical & Technical Interpersonal & Leadership Work Style & Character

• Strong analytical problem • Clear communication at all • Self-motivated and

-solving levels proactive
• Root cause analysis • Ability to manage change • Comfortable working on
mindset resistance the shop floor
• Data-driven decision • Team player and cross- • Project management and
making functional collaborator prioritisation
• Systems and process • Coaching and mentoring • Resilient under pressure

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METHOD STUDY — Comprehensive Reference Guide | Methods Engineer Job Description

thinking ability and deadlines

• Attention to detail in • Stakeholder management • Genuine commitment to
observation and influence continuous improvement

Career Progression Pathway

Level Role Title Primary Focus Typical Exp.

Entry Junior / Graduate IE Data collection, process 0 – 2 yrs

Analyst charting, time study support
Mid Methods Engineer Full method studies, project 3 – 6 yrs
leadership, standard time
setting
Senior Senior Methods / IE Strategic projects, mentoring, 6 – 10 yrs
Engineer capital investment analysis
Lead IE Manager / Plant IE Lead Department management, 10 + yrs
headcount planning, site-wide
IE strategy
Expert Head of Industrial Group-level transformation, 15 + yrs
Engineering benchmarking, innovation
roadmap

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