Time and Motion Study
Report on Case Study
12/28/20
Quaid-E-Azam College of Engineering & Technology, Sahiwal
Assignment 02
ME-432L Total Quality Management
Submitted To:
Engr. Afaq Masood
Submitted By:
Abdul Karim 2017-UET-QET-SWL-MECH-03
Nouman Rasool 2017-UET-QET-SWL-MECH-05
Ali Haider 2017-UET-QET-SWL-MECH-09
Mubasher Nouman 2017-UET-QET-SWL-MECH-10
Asad Iqbal 2017-UET-QET-SWL-MECH-15
M. Abdullah 2017-UET-QET-SWL-MECH-24
Semester:
7th
Signature: ______________
Date: ___________________
Session: (2017-2021)
Department of Mechanical Engineering
QUAID-E-AZAM COLLEGE OF ENGINEERING &
TECHNOLOGY
Department of Mechanical Engineering,
Semester
7th
Session
2017
Name: Reg. No.
ME-432L Total
Subject: Quality Management Semester: 7th
Assessment
Type Assignment 2 Marks: Time:
25
Question# 1
CLOs
CLO-1 CLO-2 CLO-4 CLO-5
Addressed
Domai
C-3 C-3 A-3 A-2
n Level
PLOs
Addressed PLO-04 PLO-9 PLO-08 PLO-10
Total
10 10 2 3
Marks of
CLOs
Obtaine
d Marks
Important Instructions / Guidelines:
Read the question carefully and answer the questions according to their
statements.
The assignment must be neat, clean and plagiarism free (Less than 15%).
Question 1:
Do a real time ‘Time and Motion’ study of any fast food restaurant in Sahiwal.
For any order, calculate and analyze the following:
• Normal Time
• Standard Time
• Performance Rating Factor (Assumed with Reason)
• Allowances (Rest, Personal and Special)
Make a graphical representation of each component as per time consumed to fulfill
the order. Also consider the method study and suggest ways on how the restaurant
can do better by adapting some other methods (which may include how they take
and process orders) or additional services they should offer to enhance
productivity.
Make sure to include a summary of the report in following format
with specific values:
Note:
1. The assignment can be submitted in groups as decided in the lab.
2. Make sure to add picture of your visit in the report.
3. Do follow the SOPs and social distancing due to COVID-19
outbreak.
Abstract:
When a person wants to purchase things, then he mostly compares the prices with those of similar
products, which are being manufactured by others. Therefore, to give competitive quotations,
estimation of accurate labor cost is very essential as it has got large effect upon the price of product.
If the price is higher, then, manufacturer may not get supply order and if it is lower, then losses
may occur. Thus, exact estimation of time is very essential for accurate pricing. As labor cost
depends upon time estimation, therefore, time is estimated correctly as far as possible.
Secondly, whenever a customer contracts for the purchase of a certain product then he desires that
the product should reach to him at a promised date which is only possible when manufacturer is
aware of the time to be taken by the product during manufacture. Therefore, to find the correct
manufacturing time for product, time study is performed by the Time Study Engineer.
The purpose of study on time and motion study is to improve skills of management as primary
target. Therefore, study is held for the focus described above.
Acknowledgement:
On the behalf of my group mates, I would like to express my special thanks of gratitude to my
teacher Engr. Afaq Masood who gave us the golden opportunity to seek by performing our efforts
on this assignment on “Time and Motion Study”, which also helped us in doing a lot of work and
we came to know about so many new things about Total Quality Management being major in
Mechanical Engineering. Further, He enable us to visit a food chain restaurant and get a survey
report to held assignment. We are impressed by his method of teaching which makes us able to be
professionals.
Further I would like to thank the administration of Crunchy Pizza, Sahiwal (Pizza shop) who
allowed us to held our case study there. We appreciate their coordination with us.
I am also thankful to platform that allow our access to their academic material.
______________
Nouman Rasool
Table of Content
Abstract: ........................................................................................................................................................ 2
Acknowledgement: ....................................................................................................................................... 3
List of Acronyms: ......................................................................................................................................... 5
List of Figures and Tables: ........................................................................................................................... 6
Introduction:.................................................................................................................................................. 7
Use of Time Study: ....................................................................................................................................... 7
Procedure for Time Study: ............................................................................................................................ 7
Analysis of Work: ..................................................................................................................................... 7
Standardization of Methods: ..................................................................................................................... 8
Making Time Study: ................................................................................................................................. 8
Standard Time: ...................................................................................................................................... 8
Rating Factor:........................................................................................................................................ 8
Performance Rating: ............................................................................................................................. 8
Allowances:......................................................................................................................................... 11
Methods of Time Study: ............................................................................................................................. 13
Stop Watch Method: ............................................................................................................................... 13
Methods of Timing by Stop-Watch: ................................................................................................... 14
Time Recording Machine: ...................................................................................................................... 15
Motion Picture Camera: .......................................................................................................................... 15
Spring Driven Camera: ....................................................................................................................... 16
Electric Motor Driven Camera:........................................................................................................... 16
Case Study: ................................................................................................................................................. 16
Materials Used: ....................................................................................................................................... 16
Procedure: ............................................................................................................................................... 17
Task 1: Set-up ..................................................................................................................................... 17
Task 2: Data Collection....................................................................................................................... 17
Task 3: Analysis .................................................................................................................................. 18
Observations and Calculations:............................................................................................................... 19
Analysis for Improvement: ..................................................................................................................... 21
Allowance: .......................................................................................................................................... 21
Performance Rating: ........................................................................................................................... 21
Conclusion: ................................................................................................................................................. 21
Bibliography: .............................................................................................................................................. 22
List of Acronyms:
R- Performance Rating
W- Stopwatch reading (continuous)
OT- Observed time
NT- Normal time
ST- Standard time
PMTS- Predetermined Motion Time System
List of Figures and Tables:
Figure 1: Stopwatch .................................................................................................................................... 14
Figure 2: Time study board ......................................................................................................................... 14
Figure 3: Time recording machine .............................................................................................................. 15
Figure 4: Crunchy Pizza Sahiwal ................................................................................................................ 17
Figure 5: Average Normal Time for each element ..................................................................................... 20
Figure 6: Standard Time Average for each element ................................................................................... 20
Table 1 ........................................................................................................................................................ 10
Table 2 ........................................................................................................................................................ 19
Introduction:
Time study may be defined as:
“The art of observing and recording the time required to do each detailed element of an industrial
operation”.
The industrial operations include manual, mental and machining operations, where:
• Manual time is divided into three types of operations, i.e. handling of tools, machines and
materials.
• Mental time includes time taken by the worker for thinking over some operations.
• Machining time includes time taken by the machines in doing its share of work.
Thus, time study standardizes the time taken by an average worker to perform these operations.
It can also be defined in the words “work measurement” is the application of techniques designed
to establish the time for a qualified worker to carry out a specified job at a definite level of
performance.
Use of Time Study:
• It is useful in determining the standard time for various operations, which helps in fixing
wages and incentives.
• It is useful to estimate the cost of a product accurately.
• It helps in production control.
• It helps in predicting accurately as to when the work will be completed and hence
customers can be promised to take delivery on a fixed date.
• Using the time study techniques, it can be found that how much machines an operator can
run.
Procedure for Time Study:
For conducting time study, average workers and average machines are selected. This study is
conducted by the Time Study expert, who should be familiar with all information’s related to the
job and the conditions in which it is being done. The location of the expert should be such that he
can watch all the operations and the movement of the workers without disturbing them from
suitable distance.
Time study is performed in the following stages:
Analysis of Work:
The complete job and its operations are split up into elements. These elements are finalized after
conducting motion study. In the end, time required for the job preparation, setting time, cleaning
of machine and oiling etc. should be included. Thus, time study includes all the tasks performed
by the worker and not only the effective work.
Standardization of Methods:
Before conducting time-study, all the elements of the job such as materials, equipment, tools,
working conditions and methods are standardized. The method should be easy, safe and quickest
in the given conditions, so that it can be accepted by workers.
Making Time Study:
The study is done on a printed time study record sheet which is fixed on a board known as Time
Study Board. On one corner generally right-hand top corner a stop watch is placed. This stop watch
should have a decimal scale dial so that it can read up to 0.01 minute.
Different time readings of one element are recorded in the corresponding column of the record
sheet. Several sets of readings are taken to arrive at an accurate result. After noting all these
readings, average time is calculated, neglecting abnormal values, if any.
This average time is multiplied by a levelling factor also called ‘Rating Factor’, which is generally
assumed as 90-120% to get the time required by a normal worker. The multiple of average time
and rating factor is known as “Normal Time”.
Some allowances such as personal allowance (20%), fatigue allowance (5%), preparation
allowance (5%) are added in normal time to obtain the standard time. The standard time is the
basis for the calculation of wages and incentives.
Thus, Standard time = (Average Time × Rating factor) + Allowances.
Standard Time:
It is the time, which is taken by a normal worker for a certain task or job, working under moderate
conditions and includes other allowances such as fatigue, setting of tool and job, repairing of tool,
checking of job etc.
Rating Factor:
Time study engineer multiplies actual time with a factor known as “Rating Factor” or “Levelling
Factor” to get the average time which a normal worker would take. This is expressed as a
percentage of the efficiency of representative operator, which indicates how efficient an operator
is in comparison to some of his average fellow workers.
Performance Rating:
Performance rating is that process, during which the time study engineer compares the
performance of the operator under observation with his own concept of normal performance.
The concept of normal performance, must be such that the time standards are set from it, are within
the capacity of the majority of workers in the enterprise.
It would be of no use in setting standards so high that only the best worker could attain them since
programs or estimates based on them would never be fulfilled.
Similarly, low standard would result very high earnings for some of the workers and consequently,
excessively high labor cost of the product and very large difference in the earnings of the workers:
Methods of Rating:
Following are the important methods used for performance rating:
• Speed Rating.
• Westinghouse System of Rating.
• Synthetic Rating.
• Objective Rating.
• Physiological Evaluation of Performance Rating.
Speed Rating:
This rating procedure consists of estimating the pace of the operator’s movements with respect to
a normal pace and is noted as a factor. This rating is applied to each element and observed time
for each element is multiplied by this factor to get the normal time for the element.
Westinghouse System of Rating:
A four-factor system of Performance Rating was developed at Westinghouse.
These factors are:
• Skill
• Effort
• Conditions
• Consistency
A scale of numerical values for each factor was supplied in tabular form, the worker was observed
while working and given a value from these tables. The time obtained from time study is then
leveled by applying the sum of the ratings of all the four factors.
Table 1
For example, if the observed time for an operator was 1.50 minutes and if the ratings are as follows:
Good skill, C1 + 0.06
Excellent Efforts, B2 + 0.08
Average condition, D + 0.00
Good consistency, C + 0.01
Total + 0.15
The normal time for that operation would be = 1.50 x 1.15 = 1.72 min.
Synthetic Rating:
In this method, performance of the worker is rated from the values already known as PMTS
(Predetermined Motion Time System). In this procedure, time study is done in the usual manner
and then actual time obtained for certain elements from this study are compared with that of known
standards.
The ratio of standard time of an element to that of observed time to the same element is rating
factor. The rating factor for the study is the average of rating factors obtained for different elements
of the study.
Efforts must be made to determine the rating factors for as many elements as possible. In this
method, it is assumed that performance for the whole of the study will be same as that obtained in
these elements.
If, R = Performance Rating factor,
P = Predetermined standard for an element,
A = Average of actual time obtained in the time study for that element,
Then,
R = P/A
Objective Rating:
In this method, Rating is done in two stages, in first stage, operator’s pace is rated, by observing
pace of movement or rate of activity, and no attention is paid for the job difficulties.
After the pace rating is done, in the second stage, an allowance of a secondary adjustment is added
to the pace rating by considering the job difficulties. Job difficulties are divided into six clauses.
A table provides the percentage of adjustments to be made for each of these six factors.
These factors are:
• Amount of body used
• Foot Pedals
• Bimanualness
• Eye-hand co-ordination
• Handling requirements
• Weight.
For example, if the selected time for an element is 0.30 minute, the pace rating is 110% and if the
sum of all secondary adjustments amounts to 20% then the normal time will be
= 0.3 × 1.10 × 1.20 = 0.396 min
Physiological Evaluation of Performance Rating:
Many studies have recently shown that there is relationship between physical work and the amount
of oxygen consumed by the operator. More recently, it has also been found that the change in heart
rate is also a reliable measure of muscular activity. This technique is however not being used now
but large number of people in various parts of the world are working on this problem.
Allowances:
To get the standard time, a proper allowance must be added undermining the working conditions.
While deciding the quantum (generally in terms of percentages) of allowance to be added to the
normal time, following types of allowances are considered:
Relaxation Allowance:
This allowance depends upon the nature of the job, and includes following two categories of
allowances:
Personal Need Allowance:
It allows worker for the necessity to go away from the work place to attend the personal needs
such as washing, going to lavatory, getting a drink etc. It is commonly taken as 5% for male and
7% for female worker.
Fatigue Allowance:
Fatigue allowance is provided to recover a worker from the physiological and psychological effect
of carrying out work.
It contains:
A constant portion, (the minimum or basic fatigue allowance) which must be adequate for a worker
who carries out the job while seated engaged on light work in ideal working conditions. This is
generally considered as 4% for both men and women.
A variable portion is added when the working conditions are severe. It is based on factors which
vary the working conditions. These factors are:
• Standing
• Use of force,
• Light,
• Air,
• Visual strain,
• Manual-strain,
• Mental strain.
Interference Allowance:
When a worker is attending more than one machine, then, interference is the time for which one
or more machine units remain idle while attendant is occupied with the work on other machine
units. The allowance provided to compensate this idleness due to interference is known as
interference allowance.
Process Allowance:
This is an allowance provided to compensate for enforced idleness during a process. This includes
loss of time due to:
• No work
• Power failure,
• Faulty material,
• Faulty tools or equipment’s.
Contingency Allowance:
This is an allowance of time to meet legitimate, irregular and infrequent items of work or delays
which cannot economically be measured correctly. It is usually taken as less than 5%.
Special Allowance:
These allowances are decided as a policy matter of management. These are allowed for activities
which are normally not a part of the operation cycles but are essential for satisfactory performance
of work.
These include for the following items:
• Start up
• Cleaning
• Shut down
• Set-up
• Change over
• Tools changing and regrinding.
Methods of Time Study:
Time study can be performed by the following methods, depending upon the accuracy required:
• Stop Watch Method
• Time Recording Machine, and
• Motion Picture Camera.
Stop Watch Method:
Stop watch used for time study purpose should be very accurate and preferably graduated in
decimals so that it can record even up to 0.01 minute. It has two hands. Large hand revolves at a
speed of one revolution per minute and its dial is divided into 100 divisions.
The small hand revolves at a speed of one revolution in 30 minutes. Dial for this small hand is
graduated in such a way that it enables to read up to one minute. The sketch of stop-watch is shown
in Fig.1
Figure 1: Stopwatch
Time study board is made of any hard wood. Its shape is such that it rests on the waist line and
offers a smooth curvature to support it with the rear arm of hand, as shown in Fig.2 This board
provides a place to keep the stop-watch on the right-hand top corner.
Figure 2: Time study board
In addition to the above equipment, a time study expert should keep a pencil, steel tape, a calculator
etc.
Methods of Timing by Stop-Watch:
To note the time with the help of stop-watch, following systems are used:
Continuous Method:
In this, the stop-watch is allowed to run continuously and at the end of each operation reading of
watch is noted and written in the Time Study Record Sheet. Thus, to get the time required for any
particular element of operation, the previous reading is subtracted from the next reading. This
method is better as it eliminates the possibilities of delay in noting the readings.
Snap Back Method:
In this method, knob of stop-watch is pressed to stop it at the end of each element of operation and
is again restarted after noting the time required for completing the previous operational element.
This method is generally opposed by workers because it gives lesser time in comparison to actual
due to repeated stops and starts of watch.
Accumulated Method:
With the help of this method direct reading of each operational element is taken by the help of two
watches connected with a lever mechanism, so that when one watch is started other automatically
stops. The reading of the stop watch is noted and in the meantime, when next operational element
is completed the second watch is started which stops the first one to facilitate in noting the readings.
Time Recording Machine:
This type of machine has a paper tape, which rotates on two rollers at uniform speed. This paper
tape is graduated in such a way that it gives timings in fraction of minutes. Readings can be seen
and recorded through a slit provided in the casing of equipment’s. By using this machine, some
errors of the stop-watch method are eliminated.
The line diagram of Time Recording Machine is shown in Fig.3
Figure 3: Time recording machine
Motion Picture Camera:
This camera as already explained is used in micro-motion study. The utility of micro motion study
has already been described in the ‘Motion Study’. This camera is driven at constant speed of
several ranges. Because of constant speed, time taken by each film can be calculated. Thus, by
knowing the number of films covered by one operational element, the exact time can be found.
For example, if camera was set at 1Q00 films per minute, i.e., each film takes 0.001 minute and if
an operational element covers 68 films then time required for this operational element would be
0.001 x 68 = 0.068 minute. Thus, this method is very accurate one but is used for high precision
work, as this is much expensive than other methods.
Following two types of Motion Picture Cameras are in common use:
Spring Driven Camera:
The speed of this camera is nearly constant and generally remains within ± 10%. Normal speed is
16 exposures per second.
Electric Motor Driven Camera:
These cameras are driven by constant speed electric motor.
Case Study:
A proper study is held in this regard to meet with process under which an engineer is go through
to standardize time study. For such purpose, study is held at a pizza shop named “Crunchy Pizza”.
The aim of this study is to get the experience in practical shape of work to held a time and motion
study.
The complete job and its operations are split up into various elements. These elements are finalized
after conducting motion study. Before conducting time-study, all the constituents of the job such
as materials, equipment, tools, working conditions and methods are standardized. The study is
done on a printed time study record sheet which is fixed on a board known as Time Study Board.
On one corner generally right-hand top corner a stop watch is placed. This stop watch is set at a
decimal scale dial so that it can read up to 0.01 minute.
During the study, “stop watch method” is adopted as one out of three methods to held time and
motion study. Stop watch method is further divided into two methods known as continuous and
snap-back method. So, Continuous method is selected due to simplicity and to avoid errors during
observed time readings.
For Performance rating, method of speed rating is adopted for this study that allows time study
engineer to calculate performance fast as possible.
Materials Used:
• Time Study Form
• Stopwatch
• Pen/Pencil
• Clipboard
Figure 4: Crunchy Pizza Sahiwal
Procedure:
Task 1: Set-up
Watch the cycle until it feels familiar with the process.
Define a clear beginning/end point of the complete assembly.
Break the rest of the elements down into clear steps. Define a clear end point for each step.
Record each step you have defined in the top row, directly adjacent of the corner labeled “Element No. and
“Description”, numbering each element in the top-left corner in the order they occur.
Get a timing device, pencil, clipboard, and the time study form. Attach the form to the clipboard. Proceed
to the area where you can observe the cycle. Set the timing device to the lap timing setting.
Task 2: Data Collection
Observe the process until the operator reaches the beginning/end point of the assembly.
Start the timer when this point occurs.
Click the lap button on the timer when the end point of each element occurs. Record the rating determined
at the end each step. Continue this process until observe 18 cycles (18 complete assemblies).
Use the recall function on timing device to view the time recorded for the first step of the first cycle. Record
this time on the time study form under the column labeled W. Continue to record sequential times in the
corresponding box until all times have been recorded.
Task 3: Analysis
Record the actual time it took to perform each individual step under the column labeled OT (observed time).
To get this time, subtract the time under the W column for the previous step from the time under W for the
step you are calculating the observed time for.
Multiply the observed time (OT) for each step by the rating. Record this number in the column labeled NT
(normal time). NT=(OT)*(Rating/100)
Refer to the Allowance section at the bottom right-hand side of the page. Record the allowances, determined
by several factors of the assembly, in the corresponding boxes. Sum these values and record in the box
labeled “Total Allowances %”.
The different allowance values can be found in many sources. The allowance is determined by the company.
So, to get this number, we’ll have to consult the regarding company.
Sum the observed times (OT column) for each step in the assembly individually. Record these values in the
Summary Section in the box labeled “Total OT” corresponding to the step.
Sum the normal times (NT column) for each step in the assembly individually. Record these values in the
Summary Section in the box labeled “Total NT” corresponding to the step.
Divide the total normal time by the total observed time for each step to calculate the rating. Record this
number in the box labeled “Rating” corresponding to the step.
Record the number of cycles observed in the box labeled “No. Observations”.
Divide the total normal time for each step by the number of occurrences. Record this value in the box
labeled “Average NT” corresponding to the step.
Record the % allowance you determined in step 3 in the box labeled “% allowance”. Use the below formula
to calculate the standard time for each step. Record this value in the box labeled “Standard Time”
corresponding to the step. Standard Time = NT*(1 + % allowance/100)
Sum the standard times you have calculated for each step and record it in the box labeled “Total Standard
Time”. This is the standard time for the cycle.
Date: 27-12-2020
Time Study Form Operation: Pizza Making
Elements Get the ball dough Flatten Dough Spin and Toss Dough Place Dough Pour Sauce Place Cheese Place Pepperoni
R W OT NT R W OT NT R W OT NT R W OT NT R W OT NT R W OT NT R W OT NT
1 100 0.15 0.15 0.15 110 0.25 0.1 0.11 80 0.6 0.35 0.28 110 1.15 0.55 0.61 100 3.3 2.16 2.16 100 5.29 1.98 1.98 110 6.24 0.95 1.05
Table 2
2 90 0.16 0.16 0.14 100 0.28 0.12 0.12 120 0.55 0.27 0.32 120 1.14 0.59 0.71 90 3.3 2.18 1.96 90 5.31 1.99 1.79 100 6.25 0.94 0.94
3 100 0.14 0.14 0.14 90 0.23 0.09 0.08 100 0.56 0.33 0.33 100 1.17 0.61 0.61 100 3.3 2.14 2.14 80 5.33 2.02 1.62 90 6.26 0.93 0.84
Total OT 0.45 0.31 0.95 1.75 6.48 5.99 2.82 Remarks: This study
Allowances
Observations and Calculations:
Total NT 0.43 0.31 0.93 1.92 6.26 5.39 2.82 is held at "Pizza
Performance Rating 96.4 100 98.3 110 96.6 89.9 100 Personal need 5% Crunch, Sahiwal"
No. of Observations 3 3 3 3 3 3 3 Basic Faitgue 4%
Average NT 0.14 0.1 0.31 0.64 2.09 1.8 0.94 Variable Fatigue
%Allowance 9 9 9 9 9 9 9 Special
Standard Time 0.16 0.11 0.34 0.69 2.28 1.98 1.03 Total Allowance % 9%
Total Standard Time 6.586833333
Figure 5: Average Normal Time for each element
Figure 6: Standard Time Average for each element
Analysis for Improvement:
The pizza shop needs to control over following observed deficiencies:
Allowance:
It has been observed that cook’s fatigue allowance is not at optimum value. The effects of fatigue
can be reduced by providing rest pauses at certain intervals, during which the body recovers from
its exertion. During these rest periods, all the employees in a department are not permitted to work.
Properly organized rest pauses are beneficial because of the following reasons:
• Rest pauses increase the production without unduly tiring the workers.
• Rest pauses tend to maintain the level of the operator’s performance nearer to the optimum
and decreases the variation in their performance, which are otherwise caused due to fatigue,
when rest pauses are not provided.
• Rest pause reduces the quantum of time often taken by the workers for attending personal
needs during working hours.
• Workers like these rest pauses because they break-up the dullness or monotony.
Performance Rating:
The pizza shop needs to improve the performance rating at some elements of pizza making process.
It is observed after calculations that four out of seven elements of pizza making cycle are less than
an average process. By taking some appropriate steps, the management can improve the first, third,
fifth and sixth element of pizza making process. It will not only reduce the time of pizza making
but also would create extra popularity point before-time pizza preparation.
Conclusion:
Time study with the help of a stop watch is the most commonly used work measurement method. Time
study is best suited for short-cycle repetitive jobs. Most of the production jobs can be easily timed by a
time-study. Work sampling gives an unbiased result since workmen are not under close observation. A
work sampling study may be interrupted at any time without affecting the results. But the observations are
limited. So, the results may not be accurate. This method normally does not record the workers' speed of
working. However, it is a good method to held time study using a stopwatch on small scale of time and
motion study.
Bibliography:
Motion and Time Study: Design and Measurement of Work
by Ralph Mosser Barnes
Google Scholar
Time Study: Definition, Objectives and Advantages
[Link]
and-advantages-with-formula/90524
Time and motion study
Wikipedia, The
Encyclopedia
[Link]
International Research Journal of Engineering and Technology
[Link]
Productivity Improvement Through Motion and Time Study
National Conference on Management of Technology and Technology Entrepreneurship
(MOTTE 2005)
[Link]
And_ Time_Study.pdf
