Methods Analysis is a systematic process of
studying how a job or task is performed to identify
and eliminate unnecessary motions, simplify the
work procedures, and ultimately improve efficiency,
safety, and quality. It focuses on the how of work.
Objectives of Methods Analysis:
• Improve Efficiency: Reduce the time and effort required to complete a
task.
• Reduce Costs: Minimize material waste, labor costs, and energy
consumption.
• Improve Safety: Identify and eliminate hazardous work practices.
• Enhance Quality: Ensure consistent and high-quality output through
standardized procedures.
• Reduce Fatigue: Design work that minimizes physical and mental strain
on workers.
• Improve Job Satisfaction: Create more ergonomic and less frustrating
work environments.
Methods Analysis Process
1. Select the Job to Be Studied
Focus on jobs that are repetitive,
have high labor costs, are prone to
safety issues, or are bottlenecks in
the process.
Methods Analysis Process
2. Gather Information: Collect all
relevant details about the
existing method, including:
• Workplace layout
• Tools and equipment used
• Materials involved
• Current procedures and steps
• Time taken for each step
• Worker movements
Methods Analysis Process
3. Record the Existing Method:
Document the current process
using various techniques.
Methods Analysis Process
4. Analyze the Recorded Data: Critically examine each step of
the process to identify inefficiencies, unnecessary motions,
and potential areas for improvement. Ask questions like:
• Can this step be eliminated?
• Can steps be combined?
• Can the sequence of steps be changed for better flow?
• Can the process be simplified?
• Is the equipment appropriate?
• Is the workplace layout optimal?
Methods Analysis Process
5. Develop Improved Methods: Based on the analysis,
propose new and more efficient work procedures. This
might involve:
• Changing the sequence of operations
• Simplifying necessary operations
• Eliminating unnecessary operations
• Combining operations
• Changing the workplace layout
• Redesigning tools and equipment
Methods Analysis Process
6. Evaluate the Proposed Methods:
Assess the feasibility, cost-
effectiveness, and potential
benefits of the new methods.
Methods Analysis Process
7. Implement the New Methods:
Train workers on the new
procedures and put them into
practice.
Methods Analysis Process
8. Follow Up: Monitor the
performance of the new
methods to ensure they are
achieving the desired
improvements and make further
adjustments as needed.
Techniques Used in Methods Analysis:
Process Flowcharts:
Visual representations of the sequence
of steps in a process
Techniques Used in Methods Analysis:
Worker-Machine Charts: Show the
simultaneous activities of workers and
machines
Techniques Used in Methods Analysis:
Activity Charts (Multiple Activity
Charts): Track the activities of two or
more workers or workers and
equipment simultaneously.
Techniques Used in Methods Analysis:
Operation Charts: Focus
on the actions performed
by a worker at a specific
workstation.
Techniques Used in Methods Analysis:
Flow Diagrams: Show the movement of
materials or workers within a
workplace layout
Techniques Used in Methods Analysis:
Motion Study: Analyzing the basic body
motions used by workers to perform
tasks.
• Therbligs: Identifying and classifying fundamental motion elements
(e.g., reach, grasp, move, release).
• Micromotion Study: Using film or video to analyze very fine motions
Techniques Used in Methods Analysis:
Work Sampling: Observing a worker
at random intervals to determine the
proportion of time spent on different
activities.
Techniques Used in Methods Analysis:
Ergonomics Analysis: Considering the
human factors and designing work to
fit the worker's capabilities and
limitations.
Techniques Used in Methods Analysis:
Value Stream Mapping: A lean tool
that visualizes the flow of materials
and information from customer order
to delivery.
Techniques Used in Methods Analysis:
Simulation: Using computer models
to analyze and experiment with
different process designs.