Employee Productivity

Productivity = Quantity of products or services produced Amount of resources used Inputs in any production process comprise capital, labor, materials and energy. Such measurement gives partial productivity Partial Productivity = Output in a given period Labor hours used in the period Productivity of all resources put together gives productivity on the total factor basis. This method of calculating productivity considering all the resources is called multi-factor approach to measuring Productivity Total Productivity = Output in a given period (Labor + Capital + Materials + Energy hours used in the period)

Labor Productivity: The different ways of measuring labor Productivity 1. Output per man-hour Labor Productivity = Output Man-hours used 2. Labor hours per unit of output Labor Productivity = Total labor hours used Output 3. Added value per unit of labor cost Labor Productivity = Added value for the product Total wages


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Variables affecting Labor Productivity Employees job performance: employee ability and motivation Physical work environment: Technology, machines, tools and work methods that support and assist their work Product quality: defects, scrap and rework


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Ways of improving Productivity Learning curves Safety and health Incentive schemes

Learning Curves
It is based on the premise that as an organization gains experience in manufacturing a product, the resource inputs are required per unit of output diminish over the life of a product These concepts are based on three under-pinnings 1. Where there is life, there can be learning 2. The more complex the life, the greater the rate of learning 3. The rate of learning can be sufficiently regular to be predictive


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It is possible to estimate: The average number of labor-hours required to produce n units in a production run The total number of labor-hours required to produce n units in a production run The exact number of labor-hours required to produce the n unit of production run
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Three approaches to Learning curves Arithmetic Analysis Logarithmic Analysis Learning Curve Tables

Arithmetic Analysis is the simplest approach learning curve problems, because it is based on the fundamental concept : As the number of units produced doubles, the labor-hours per unit decline by a constant factor In Logarithmic Analysis, the time taken to th produce the n unit (Tn) is given by, Tn = T1(nb) , where T1 is the labor-hours to produce the first unit and b is the slope of the learning curve and is given by b= log r log 2 , r is the learning rate percentage

The learning-curve coefficients that allow us to th compute not only the labor-hours for the n unit in a production run but also the total laborth hours for the entire production run where the n unit is the last unit in the production run

Employees safety and health

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Safety: A typical safety program comprises five elements, Development of policies, procedures and training systems Creation of an organization to ensure safety Analysis of the causes and occurrence of accidents Implementation of the safety program Evaluation of the effectiveness of the program

Health is affected by the surroundings, job stress, noise, alcoholism, drug abuse Impact on productivity, absenteeism and turnover Sections 11 to 20 of the Factories Act 1948 deals with the health of the workers

Incentive Payments

The primary objective of incentives is the inducement and motivation of workers for higher efficiency and greater output Other advantages are reduced supervision, better utilization of equipment, reduced scrap, reduced lost time, reduced absenteeism and turnover and increased output

Work Study
Methods

Study Work Measurement

Work Study is defined as that body of knowledge concerned with the analysis of the work methods and the equipment used in performing a job, the design of an optimum work method and the standardization of proposed work methods. A systematic, objective and critical examination of the factors affecting productivity for the purpose of improvement Make use of techniques of methods study and work measurement to ensure the best possible use of human and material resources in carrying out a specific activity

Objectives of Work Study - To analyze the present method of doing a job, systematically in order to develop a new and better method - To measure the work content of a job by measuring the time required to do the job for a qualified worker and hence to establish standard time - To increase the productivity by ensuring the best possible use of human, machine and material resources and to achieve best quality/service at minimum possible cost - To improve operational efficiency

Benefits of Work Study - Increased productivity and operational efficiency - Reduced manufacturing costs - Improved work place layout - Better manpower planning and capacity planning - Fair wages to employees - Better working conditions to employees

- Improved work flow - Reduced material-handling costs - Provides a standard of performance to measure labor efficiency - Better industrial relations and employee morale - Basis for sound incentive schemes - Provides better job satisfaction to employees

Basic procedure of Work study

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There are Eight steps in performing a complete work study Select the job or process to be studied Record or collect all the relevant data about the job or process, using the most suitable data collection techniques ( Operation process chart, flow process chart, flow diagram, SIMO chart, man-machine chart) so that the data will be in the most convenient to be analyzed.

3. Examine the recorded facts critically and challenge everything that is done; the purpose of activity; the place where it is done; the sequence in which it is done; the person who is doing it; the means by which it is done 4. Develop the most economic method, taking into account all the circumstances and drawing as appropriate on various production management techniques 5. Evaluate the results attained by the improved method compared to the quantity of work involved and calculate the standard time for it.

6. Define new method and the related time and present it to all those concerned, either verbally or in writing, using demonstrations 7. Install the new method, training those involved, as an agreed practice with the allotted time of operation. 8. Maintain the new standard practice by monitoring the results and comparing them with the original targets.

Method Study
To simplify the job and Develop more economical Methods of doing it

Work study

Work Measurement
To determine how long it should take to carry out

Higher productivity

Method Study

It is a scientific technique of observing, recording and critically examining the present method of performing a task or job or operation with the aim of improving the present method and developing a new and cheaper method. It is also known as Methods improvement or Work improvement. It encompasses the study of work processes, working conditions and equipments and tools used to carry out the job

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Objectives To study the existing/proposed method of doing any job, operation or activity To develop an improved method to improve productivity and to reduce operating costs To reduce excessive materials handling or movement and thereby reduce fatigue of workmen To improve utilization of resources To eliminate wasteful and inefficient motions To standardize work methods or processes, working conditions, machinery, equipments and tools


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Advantages of Method Study Work simplification Improved working method Better product quality Improved workplace layout Improved equipment design Better working conditions/ environment Better materials handling and lesser materials handling costs Improved work flow

9. Less fatigue to operate 10. Optimum utilization of all resources 11. Higher safety to workmen 12. Shorter production cycle time 13. Higher job satisfaction to workmen 14. Reduced material consumption and wastages 15. Reduced manufacturing cost and higher productivity

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Method Study Procedure Select- have maximum economic advantage, offer vast scope for work improvement, working conditions and improving utilization of resources Record- relevant facts using process charts and/or diagrams Examine- questioning Purpose (what is achieved?) Means (how it is achieved?) Sequence (when it is achieved?) Place (where it is achieved?) Person (who achives it?)

4. Develop- the factors to be considered are - Cost of implementation - Expected savings in time and cost - Feasibility - Producibility - Reaction of employees to the new method - Acceptance to design, production planning and control, QC - Short or long term implication of the alternative 5. Install- three phases- Planning, arranging, implementing 6.Maintain


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Process Charts used in Method Study Outline Process Chart Operation Process Chart Flow Process Chart Two handed Process Chart Multiple Activity Chart The Man-Machine Chart/ Worker- Machine Chart Flow Diagram String Diagram Simultaneous Motion Cycle (SIMO) Chart

Motion Study

It is the science of eliminating wastefulness, resulting from using unnecessary; ill-directed and inefficient motion. The aim of motion study is to find and perpetuate the scheme of the least waste methods of labor Micro motion study provides a valuable technique for making minute analysis of those operations that are short in cycle, contain rapid movements and involve high production over a longer period of time

To analyze the inter-relationship among the members of a work group To study the relationship between an operator and the machine which he works To obtain the time for an operation To establish a permanent record of the method of doing a job The usual procedure of performing a micromotion study is to take motion picture of the operations, analyze the film and to prepare a SIMO chart from the results of the film analysis. In analyzing the film, very small time values

may be obtained by reading a clock that appears in each of the motion pictures The film is analyzed by breaking the job cycle into micro-motions or Therbligs, which indicate the basic body motions of the workers When the motion begins, The nature of the motion and When the motion ends A therblig is the name for one of a set of fundamental motions required for a worker to perform a manual operation or task. The term Therblig is an anagram of "Gilbreth" and was coined by Frank and Lillian Gilbreth

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The set consists of 18 elements, each describing a standardized activity. Search (Sr) Select (St) Grasp (G) Transport Empty (TE) Transport Loaded (TL) Hold (H) Release Load (RL)

8. Position (P) 9. Pre-position (PP) 10. Inspect (I) 11. Assemble (A) 12. Disassemble (DA) 13. Use (U) 14. Unavoidable Delay (UD) 15. Avoidable Delay (AD) 16. Plan (Pn) 17. Rest for overcoming fatigue (R) 18. Find (F)

Work Measurement

Work Measurement is defined as the application of techniques designed to establish the work content of a specified task by determining the time required for carrying out the task at a defined standard of performance by a qualified worker It the technique applied to determine the amount of time necessary for a qualified worker to perform a particular task

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The objectives of Work Measurement can be achieve: Improved planning and control of activities or operations More effective manning of the plant Reliable ideas for labor performance Reliable basis for labor cost control Basis for sound, incentive schemes

Qualified Worker

A qualified worker is one who is accepted as having the necessary physical attributes, possessing the required intelligence and education and having the required skill and knowledge to carry out the work in hand to satisfactory standards of safety, quantity and quality International Labor Organization (ILO)


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Techniques of Work Measurement Direct Time Study Synthesis Method Analytical Method Pre-determined Motion Time System (PMTS) Work Sampling or Activity Sampling or Ratio Delay Method

Time Study

The main objective is to determine by direct observation, the quantity of human work in a specified task and hence to establish the standard time, within which an average worker working at a normal pace should complete the task using a specified method

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Time Study by Stop Watch Select the job to be studied Select the worker to be studied Conducting stop watch time study - repetitive - occasional - constant - variable - manual - machine - governing - foreign

Synthesis Method

To estimate standard time for new jobs To estimate production time for determining the prices of products to be sold Used as a basis for designing incentive schemes

Analytical Method

It is a technique of work measurement to determine the time values for jobs, having long and non-repetitive operations. Helps in planning and scheduling the production Provides a basis for fixing the labor rate for non-repetitive jobs Steps to improve labor control

Pre-determined Motion Time Study

It is a technique of work measurement by which normal or basic times are established for basic human motions and these time values are used to build up the time for a job at a defined level of performance Methods Time measurement: TMU=10 -5 hour

Work Sampling

It is a work measurement technique that randomly samples the work of one or more employees at periodic intervals to determine the proportion of total operations that is accounted for in one particular activity It is based on statistical theory of random sampling and probability of ND and also confidence level associated with standard deviation