Industrial Engineering (2161907)

(BE III, VI SEM, MECH ENGG.)

(6 – B)

Assignment
Q-1 what is productivity? What are the factors affecting
productivity.
 Productivity :-

Many researchers have defined productivity in various terms. Following are

some of the definitions of productivity:-

 Productivity is about how efficiently a firm can increase its output without
increase in inputs. Inputs include men, machine and materials.
 Productivity is a function of producing more and more output with less and
less consumption of resources.
 In volumetric measures, productivity is the ratio of output volume to the input
volume.
 According to Peter Drucker, "Productivity means a balance between all
factors of production that will give the maximum output with the smallest
effort."

 factors affecting productivity:-

Technical factors: Productivity largely depends on technology. Technical factors
are the most important ones. These include proper location, layout and size of the
plant and machinery, correct design of machines and equipment, research and
development, automation and computerization, etc. If the organization uses the latest
technology, then its productiveness will be high.

Production factors: Productivity is related to the production-factors. The

production of all departments should be properly planned, coordinated and
controlled. The right quality of raw-materials should be used for production. The
production process should be simplified and standardized. If everything is well it
will increase the productiveness.

Organizational factor: Productivity is directly proportional to the organizational

factors. A simple type of organization should be used. Authority and Responsibility
of every individual and department should be defined properly. The line and staff
relationships should also be clearly defined. So, conflicts between line and staff
should be avoided. There should be a division of labour and specialization as far as
possible. This will increase organization's productiveness.

Personnel factor: Productivity of organization is directly related to personnel

factors. The right individual should be selected for suitable posts. After selection,
they should be given proper training and development. They should be given better
working conditions and work-environment. They should be properly motivated;
financially, non-financially and with positive incentives. Incentive wage policies
should be introduced. Job security should also be given. Opinion or suggestions of
workers should be given importance. There should be proper transfer, promotion and
other personnel policies. All this will increase the productiveness of the
organization.

Finance factor: Productivity relies on the finance factors. Finance is the life-blood
of modem business. There should be a better control over both fixed capital and
working capital. There should be proper Financial Planning. Capital expenditure
should be properly controlled. Both over and underutilization of capital should be
avoided. The management should see that they get proper returns on the capital
which is invested in the business. If the finance is managed properly the
productiveness of the organization will increase.

Management factor: Productivity of organization rests on the management factors.

The management of organization should be scientific, professional, future-oriented,
sincere and competent. Managers should possess imagination, judgment skills and
willingness to take risks. They should make optimum use of the available resources
to get maximum output at the lowest cost. They should use the recent techniques of
production. They should develop better relations with employees and trade unions.
They should encourage the employees to give suggestions.

Government factor: Productivity depends on government factors. The management

should have a proper knowledge about the government rules and regulations. They
should also maintain good relations with the government.

Location factor: Productivity also depends on location factors such as Law and
order situation, infrastructure facilities, nearness to market, nearness to sources of
raw-materials, skilled workforce, etc.
Q-2 What are the reasons for low productivity?
 Wastage of recourses.
 Poor planning of layout.
 Unscientific selection and training of workers.
 Poor working condition.
 Low motivation of workers.
 Absence of mutual co-operation between employees and employers.
 Complex procedures of work.
 Poor design of product and machine.

Q-3 What is work study? Explain the concept of work study.

 work study :-
 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.
 Every organization wants to achieve higher production from less material
consumption. So, for that it is required to increase the productivity. Work
study is the tool which is being used by the industry in order to find out the
best and most efficient way of doing work using available resources.
 Work study is consisting of two major areas: First one is the method study and
second one is the work measurement.

 concept of work study :-

 Work study involves analysis of work done by the workers on shop floor and
the aim of it is to find out the best method which reduces the overall time,
reduces waste and increases overall productivity. So, overall profit of the
organization will rise. Despite of having many benefits to both (labours as
well as to the management) it is difficult to have favour from both (tabors as
well as to the management).

Following are disbelieved threats of work study in mind of workers:

  Workers believe that higher productivity will lead to unemployment.
Therefore labour always initially resists the work study implementation.
 As a tendency of human being, labour will always resist the change in the
existing system.

So, before applying work study following steps is advised:

 Proper consulting of labour has to be done such that they do not fear about
unemployment.
 The representatives must be fully taken in confidence about what is going to
happen. They must be clearly taken into faith that due to work study no
harmful actions will be adopted. If they are taken in confidence, then they will
also explain to the workers.
 Workers should have knowledge that ultimate implementation will result in
higher earnings.
 As a tendency that workers will always have opposed to the change, so they
are required to be properly explained about its advantages. Even after that the
old workers have resistance, and then they should be left out of change.
 When any worker is observed for his work by stop watch, he will be under
pressure. So, his performance will be affected. To avoid this pressure, worker
must be clearly informed that he must not be disturbed.

Q-4 What are the advantages and application of work study?

 Application of work study
1. Industries ( Production operation, research and development),
2. Marketing, Sales and distribution,
3. Offices, stores and Warehouses,
4. Material handling,
5. Design,
6. Building and other constructions,
7. Transport,
8. Hospital,
9. Army, and
10.Agriculture, etc.
  Advantages work study
1. Uniform and improved production flow,
2. Higher productive efficiency,
3. Reduced manufacturing costs,
4. Better service to customers,
5. Job security and job satisfaction to workers,
6. Better working and other condition, and
7. Higher wages to workers.

Q-5 Explain the objection and basic procedure for method study.
 Objectives of method analysis:

 Method study is systematic investigation of existing methods of doing job and

from that the aim is to develop and install an easy and efficient procedure for
doing the same job. So, we can summarize the objectives of method study as
follows:
1. To improve the present method of doing the job'
2. To reduce unnecessary movements of men, machines and materials.
3. To change the plant layout in order to change the method of doing the job and
so plant layout will be improved'
4. To improve utility of men, machines and materials'
5. To improve overall working environment'
6. Economy in human effort and the reduction of unnecessary fatigue.
7. Improvement in quality of products.

 Procedure of method study

 Method study involves investigation of the existing methods of performing

the job and critical evaluation of factors affecting the job. Then after it
develops new methods of performing the job. Once new method is developed,
it is required to implement the method and then maintain the new method.
This whole procedure can be subdivided as steps as explained below:

1. Selection of the job

2. Record all the activities of that job
 3. critical investigation of activities related to the job
4. Development of alternatives methods & selection of most economical method
5. Implementation of new method
6. Maintain the new method

 These are explained below.

1. Selection of the job

 For studying is very crucial aspect. Since industries has number of jobs to be
performed, it is very important is select which job is required to be taken for
study.
 Following are the criteria for selecting a particular job for study:

 Clear evidence of potential cost reduction

 Jobs having high level of scrap and reprocessing cost
 Jobs having high level of bottleneck
 Jobs having more rejection or complaints from customers
 Jobs having inconsistency in quality

 Jobs manufactured by conventional methods

 Jobs which causing high level of fatigue to the workers

2. Record all the activities that job

 Once the job is selected by authorities considering all criteria, the next step is
to study that job thoroughly. For studying the job, it is required to gather all
the information related to the job such as input data, different process to be
performed on the job, record of activities involved in performing the job etc.
 Here, the important is to record of all activities involved in the job- for
recording the job various tools and techniques are used. These tools and
techniques involves motion of men, material and machines. Once all input
information are collected than critical examination of the activities are carried
out.
3. Critical investigation of activities related to the job

 The success of investigation depends on the perfection of input data and

recording of activities on tools and techniques. If the input data and
information is perfect, than investigation can give better results.
 The objective of critical examination of recorded facts of an existing method
is to determine the true reasons behind each events. Critical examination
involves two types of questions: Primary questions and
 Secondary questions. Primary questions are generally asked for as follows:
 Purpose of the job (Whether it is essential or not)
 Means of doing job (Are device, tools, material for doing the job is
right?)
 Sequence of doing job (Is the sequence followed is right?)
 Place of doing job (Is the place of doing job is right?)
 Men doing the job (Is person doing the job is perfect?)
 In secondary questions, using brainstorming activity is carried out in order to
find out the alternates of present scenario which can improve the present
method of doing the job.

4. Development of alternatives methods &i selection of most economical method

 Based, on brainstorming arid examination of alternatives several alternative

methods arc selected for examination. Those selected methods arc critically
evaluated by higher authorities and based on considering various factors the
most economical method is selected for implementation as replacement of the
current method of doing job.

5. Implementation of new method

 Once the alternative method is selected, the plan of implementing that new
method in It may require to do necessary modification or changes of tool place
of current changes of tools, prepare method devices, materials, plant
implementation plant layout.
 Once all arrangements and changes are made, few trials are carried out in
order to check that whether new method is fulfilling the objective or not. If
required the alternate may be slightly modified after trials. After adopting the
new method it is implemented in full flange by concerned persons.
6. Maintain the new method

 Once the new method is implemented, it is necessary to keep watch that

whether new method is followed by the worker or not. Since workers arc
adequate with old methods of doing the job, they have tendency to slip back
into previous method. Also, the results related to change in method should be
measured in order to confirm the success of method analysis. So, continuous
inspection of new method is required in initial period after the
implementation.

Q-6 Explain different recording techniques.

 As mentioned in the second step of method analysis, certain tools and

techniques are used to record the activities. Following are different kinds of
charts and diagrams are used as recording techniques as shown in table.

Activity Symbol Meaning

Operation Operation represents that any
process is carried out on the
material. So, there is change in
the condition of the material.
Here, the material is not idle.

Inspection Inspection represents that the

produced item is checked for its
quality in terms of specification
and end users.

Final outcome of inspection

either leads to acceptance or
rejection of the product (or part).
Transport Transportation indicates the
movement of workers, materials
or equipment from place to place.
Any movements of raw material
or machines or men is represented
using this symbol.

Delay Delay indicates that the schedule

of the product is disturbed due to
any reason such as absent of
worker, due to not availability of
machine or due to any other
reason, the product is kept in its
previous condition. It is sometime
also termed as temporary storage

Storage Storage is done either for raw

materials or finished products.
Any form of products is only
processed after getting any
authorized orders. No further
action is taken it any order comes.

Inspection and operation When two activities are carried

out simultaneously on the raw
material, symbols for those
activities are combined.

Here, the symbol represents

combined inspection with
operation.

Operation and transport Here, two activities are

Combined: operation and
transport of raw materials.
Q-7 Explain different types of charts with proper understanding?

 Different types of charts :-

1. Outline process Charts
2. Flow process charts
3. Two Handed process charts
4. SIMO chart
5. Multiple activity charts
1. Outline process charts
 An outline process chart is a process chart which gives an overall view of a
process by recording only the main operations and sequences in proper
sequence. So, its obvious that such a chart requires only symbols for
‘Operations’ and ‘inspection’. A brief note of the nature of each inspection
and operations is written alongside the symbol. Allowed time where ever,
known, can also be added.
 Everything is clear from Outline process chart for assembly of two plates with
rivets is shown. As it is clear, only operations and inspection are considered
herd.

2. Flow Process charts

 A flow process chart can be prepared in similar manner as to prepare outline

process chart. A flow process chart is a process chart indicating the sequence of
the flow of a product by recording all the events with the help of process chart
symbols.

Flow process charts are divided into three groups:

(i) Man Type Flow process chart-Records what the worker does.

(ii) Material Type Flow process chart- Records what happens to material.

(iii) Equipment Type Flow process chart- Records how the equipment is used.

 So, in addition to symbols used in outline process charts, transport, delay and
storage symbols are also used in these charts. Operations defined per sheet in
these charts are usually less than the operations defined per sheet in outline
process chart because of the greater details.

 A flow process chart is identified from its title “Flow process chart” which is
written at the top followed by Man/Material/Equipment type. Other
information’s like the operation, part number, method under consideration
(present or proposed), date and name of person doing the charting and approving
are given below the title.
 3. Two Handed process charts

 It is a motion study where the motions are analyzed in performing an activity. The
aim of this investigation is to eliminate or reduce the unwanted motion to minimum
and to arrange the best of motions in a possible sequence. Two handed process
chart is also known as Left and Right Hand process chart. As the name suggests,
activities of a worker’s hand are recorded with respect to each other. This usually
comes into picture when the work involves repetitive and short operations.
 Symbols to be used are name as in other charts but the meanings of the symbols
are changed accordingly.

4. SIMO chart

 SIMO” stands for simultaneous-Motion Cycle chart. It is one of micro motion study
devised by Gilbreth and it presents graphically the separable steps of each pertinent
limb of the operator under study. It is an extremely detailed left and right hand
operation chart.

 It records simultaneously the different therbligs performed by different parts of the

body of one more operators on a common time scale. The movements are recorded
against time measured in “Winks” (1 wink= 1/2000 minute). These are recorded by a
“Wink Counter” positioned in such a location that it can be seen rotating during
filming process.
 5. Multiple activity charts

 Multiple activity chart is prepared to record the activities of men and/or machines when
one man is operating more than one machine or when one job is being processed by
more than one person. Here the activity is plotted on common time scale.
 Multiple activity charts arc prepared with the following objectives:
 To detect idle time on machines or on the part of workers.
 Based on tracking idle time, this chart helps in calculating the number of
workers required in a group to perform the job.
 Also, from calculation of idle time, it is possible to calculate number of jobs
that can be performed by a single operator.
 Multiple activity chart is following types based on the combination of man and
machine:

1. Man Machine chart

2. Man- Multi-machine chart

3. Multi-man chart on a single job

4. Multi-man- single Machine chart

 Steps for constructing the multiple activity chart as follows:
 In multiple activity chart common time scale is prepared all man and/ or machine.
 In multiple activity chart, each number of man and machine is calculated as one
subject. For each subject, a single vertical column is prepared.
 For Each subject respective activities are divided into number of small elements.
For each small element time is calculated using stop watch.
 Here the activity is either termed as working or idle. The working activities is
shown as hatched area and for the idle time it is kept as blank.
 On the column, of each subject, activities related to corresponding subject is
recorded on a common time scale.
 A brief description of each activity is mentioned in the chart.
Q-8 Write Short note on Therbligs?

 Frank and Lillian Gilbreth developed the concept of "Therbligs" to improve

production methods. Therbligs comprise a system for analysing the motions
involved in performing a task. The identification of individual motions, as well as
moments of delay in the process was designed to find unnecessary or inefficient
motions and to utilize or eliminate even split-seconds of wasted time.
 Each Therbligs has fixed symbol, colour and explanation of each. Therbligs are
used along with SIMO chart in order to find out that which motion is taking long
time along with reason. Based on that, the ways of reducing the time taking
process is applied on the lengthy activity. Following are different types of
Therbligs.

Fig: Table Therbligs

Q - 9 What is work measurement? what are the objectives of work
measurements?

 Work measurement is concerned with the determination of the amount of

time required to perform a unit of work. Work measurement is very
important for promoting productivity of an organization. It enables
management to compare alternate methods and also to do initial staffing.
Work measurement provides basis for proper planning.
 Since it is concerned with the measurement of time it is also called ‘Time
Study’. The exact examination of time is very essential for correct pricing.
To find the correct manufacturing time for a product, time study is
performed. To give competitive quotations, estimation of accurate labour
cost is very essential.
 It becomes a basis for wage and salary administration and devising incentive
schemes.

 Objectives of Work Measurement

 To compare the times of performance by alternative methods.

 To enable realistic schedule of work to be prepared.
 To arrive at a realistic and fair incentive scheme.
 To analyse the activities for doing a job with the view to reduce or eliminate
unnecessary jobs.
 To minimise the human effort.
 To assist in the organisation of labour by daily comparing the actual time
with that of target time.
Q.10 Explain techniques of work measurement.
Various techniques of work measurement are

1. Time study (stop watch technique)

2. Synthesis

3. Work sampling

4. Predetermined motion and time study

5. Analytical estimating

1. Time Study :-

The time study is a classical stopwatch study involves timing a sample of a worker's
performance and using it to set a standard. The standard time is the time required by
an average worker to perform a job once, Time study was proposed by Frederick W.
Taylor in 1881.

It requires trained and experienced observers to measure the time because the
standard time cannot be set before the work is performed. More appropriate when
the task is repetitive in nature.

2. Work Sampling :-

Estimates the percentage of time that worker spends on various activities.

Developed by L. Tippet in 1930s. Used to analyses the jobs that have non-repetitive
elements. Also used to determine ratio delay which is the percentage of time a
worker is delayed or idle. Work sampling involves random observations to record
the activity that the worker is performing. Work sampling helps in determining how
employees allocate their time. So, the study can be utilized to set staffing levels,
reassign duties, estimate various costs and set delay allowances. Easier approach and
less expensive than time study.
 3. Pre-determined motion and time systems (PMTS) :-

PMTS is one of work measurement method of finding out the standard data for
doing the job at a defined level. There are two types of standard data: Macro Data
and Micro Data. Macro data is type of standard data in which the macroscopic
method is used to calculate standard time for doing the job, while in case of micro
data microscopic method is used to calculate standard time. Generally, .in any
industry there are too many jobs which are similar in nature (for example, drilling a
hole in material). So, it is necessary to develop the standard data for the same
repeating the job.

4. Method-Time Measurement (M-T-M) :-

One of the method of PMTS is MTM. In this method, for each motion certain
predetermined value is assigned and when that particular method is in the job,
predetermined time value is calculated as standard value of doing that motion. So,
for calculating the time for doing the job, job is broken down into number of motions
and predetermined time values are added.

Q.11 What are the different types of elements for breaking the jobs?
What are the reason for breaking the job and what are the
rules for breaking the jobs?
 For calculating the time for doing the job, job is broken down into number of
motions and predetermined time values are added. MTM has 19 fundamental
motions as given below:

A. Basic Movements

Reach – R Move – M Apply Pressure – AP Position – P

Grasp – G Release – RL Turn – T Disengage – D

B. Pedal movements

Walk Turn body Bend Kneel on one leg

Kneel on both legs Stoop Sit Foot motions

 C. Two- eye movements

 Basic movements
All movements have predetermined time and based on its classes of hardness of
particular time is considered for calculation of standard time.

1. Reach (B):- In reach, hand moves to destination with a predefine objectives. The
time for reach depends- upon the nature moved, nature of destination
and also on type of reach.

2. Move (M):- Move involves transporting an object to a definite location.

3. Apply pressure (AP):- Apply pressure involves the requirement of effort for
overcoming any resistance for doing work.

4. Position (P):- Position means to align, orient or engage an object with another
object.

5. Grasp (G):- Grasp means picking up an object.

6. Release load (RL):- It occurs when the fingers do not have control on an object.

7. Disengage (D):- It means to bleak the contact between two objects.

8. Turn (T):- Turn is a motion employed to turn hand either empty or loaded about
the axis of forearm

Q.12 Explain the concept of rating.

 During the time study, time study engineer carefully observes the performance
of the operator. This performance seldom conforms to the exact definition of
normal or standard.
 Therefore, it becomes necessary to apply some 'adjustment' to the mean
observed time to arrive at the time that the normal operator would have taken
to do that job when working at an average pace.
 This 'adjustment' is called Performance Rating. Determination of performance
rating is an important step in the work measurement procedure.
  It is based entirely on the experience, training, and judgment of the work study
engineer. It is the step most subjective and therefore is subject to criticism.
 Performance Rating can be defined as the procedure in which the time study
engineer compares the performance of operator(s) under observation to the
Normal Performance and determines a factor called Rating Factor.
𝑜𝑏𝑠𝑒𝑟𝑣𝑒𝑑 𝑝𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒
Rating factor = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑝𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒

Q.13 What are different types of allowances? Explain them.

Generally allowances are classified in major three categories:

1. Personnel allowances/ Relaxation allowances: In order to meet his personal

needs, workers are visit the drinking water areas and wash rooms. So, depending
upon the working conditions personnel allowances are added in normal time.
Generally up to 5o/o of normal time is added at personnel allowance. Where working
conditions are tardier, more allowance is added.

2. Fatigue allowances: As the day passes, weariness of person is increases in both

ways, mentally and physically. It adversely affects the pace of doing work. Hence,
as the day progresses, the time required for doing the same job compared morning
is increasing. This may be due to unhealthy working conditions, physical exertion
etc. So, fatigue allowances are added considering the nature of work, working
conditions and worker's general ability of doing work.

3. Delay allowances/ Contingency allowances: Delays can be of two types:

Intentional delays and unintentional delays. Intentional delays is due to the attitude
of the worker of doing the work or not. Unintentional delays are beyond the control
of the operator. Since intentional delays are causing loss of production to the
organization, it is not calculated in the allowances.

4. Special Allowances: These allowances are given under certain special

circumstances. Some of these allowances and the conditions under which they are
given are:
5. Policy Allowance: Some companies, as a policy, give an allowance to provide a
satisfactory level of earnings for a specified level of performance under exceptional
circumstance. This may be allowed to new employees, handicap employees, workers
on night shift, etc. The value of the allowance is typically decided by management.

6. Small Lot Allowance: This allowance is given when the actual production period
is too short to allow the worker to come out of the initial learning period. When an
operator completes several small-lot jobs on different setups during the day, an
allowance as high as 15 percent may be given to allow the operator to make normal
earnings.

7. Training Allowance: This allowance is provided when work is done by trainee

to allow him to make reasonable earnings. It may be a sliding allowance, which
progressively decreases to zero over certain length of time. If the effect of learning
on the job is known, the rate of decrease of the training allowance can be set
accordingly.

8. Rework Allowance: This allowance is provided on certain operation when it is

known that some percent of parts made are spoiled due to factors beyond the
operator's control. The time in which these spoiled parts may be reworked is
converted into allowance

Q.14 How can you determine standard time?

 Standard time is the time allowed to an operator to carry out the specified task
under specified condition and defined level of performance. This is a standard
definition for standard time. Some additional time is added to basic time to arrive
standard time of a task. In practice none can work throughout the day without
taking rest. Operators need time for relaxation from fatigue. Various allowances
are relaxation allowance, contingency allowance.
Q.15 What is work sampling? Explain its advantages and
disadvantages.
 Developed by L. Tippet in 1930s. Used to analyses the jobs that have non-
repetitive elements. Also used to determine ratio delay which is the percentage
of time a worker is delayed or idle. Work sampling involves random
observations to record the activity that the worker is performing. Work
sampling helps in determining how employees allocate their time.
 Advantages of Work Sampling
 The activities which are impractical or costly to measure by time-study can be
measured readily by work sampling.
 A single observer can make work sampling study of several operators or
machines.
 The cost and time involved in work sampling study is quite less as compared
to that required for continuous time study.
 A work sampling study may be interrupted at any time without affecting the
results.
 There is less chance of obtaining misleading results as the operators are not
under close observations.
 Work sampling studies are less tedious and cause less fatigue to the observer.
 It is not necessary to use trained time study observer.
 Stop watch or other timing devices are not required for work sampling
studies.
 Disadvantages of work sampling
 Work sampling does not permit finer breakdown of activities and delays. It
can't provide much detailed information.
 It is economical and practicable only when a large number of operators are
observed, or for studying operators or machines located over wide areas.
 In certain kinds of work sampling studies, the record of method used by the
operators is not made.
 Therefore, whenever a method change occurs in any element an entirely new
study must be made.
 Management and workers may not understand statistical work sampling as
readily as they do time study.
Q.16 What is ergonomics? What are the important factors for
consideration of ergonomics?
 Ergonomics is the science which deals with human and his working
environment. Ergonomics considers the effect of working environment on
the performance of doing that job. Ergonomics is also termed as industrial
psychology. It combines knowledge of psychologist, physiologist, engineer,
anthropologist and bio-mertician. In general sense, ergonomics studies the
effect of health and safety on worker. Obviously, bad working conditions will
lead to poor performance of the worker and hence productivity of the worker
is reduced. On the other hand, if the working conditions are pleasant then it
will automatically create interest of person in doing the job and hence the
productivity increases.

 The important factors for consideration of ergonomics.

 To optimize the integration of man and machine in order to improve
productivity and accuracy.
 To develop work place which fits with the needs of worker.
 Arrangement of tools and equipment's such that it minimizes mental and
physical strain on the worker by increasing the efficiency.
 To reduce the fatigue of human while doing the job.
 To attempt the minimization of risk of injury, illness and accidents without
losing productivity.

Q.17 what are the principles of job evaluation? What are the
methods of job evaluation?
According to Kress, these principles are:
1. Rate the job and the jobber. Each element should be rated on the basis of
what the job itself requires
2. The elements selected for rating purposes should be easily explainable in
terms and a few in numbers as will cover the necessary requisites for every
job without any overlapping
 3. The elements should be clearly defined and properly selected
4. Any job rating plan must be sold to foremen and employees. The success in
selling it will depend on a clear-cut explanation and illustration of the plan
5. Foreman should participate in the rating of jobs in their own departments
6. Maxim mum co-operation can be obtained from employees when they
themselves have an opportunity to discuss job ratings and
7. Too many occupational wages should not be established. It would be unwise
to adopt an occupational wage for each total of point values.

Methods of job evaluation

(i) Ranking Method
(ii) Classification Method
(iii) Factor comparison Method
(iv) Point Rating Method

Ranking Method:- This is simplest form of job evaluation method. The method
involves ranking each job relative to all other jobs, usually based on some overall
factor like „job difficulty‟. Each job as a whole is compared with other and this
comparison of jobs goes on until all the jobs have been evaluated and ranked. All
jobs are ranked in the order of their importance from the simplest to the hardest or
from the highest the lowest. The importance of order of job is judged in terms of
duties, responsibilities sand demands on the job holder.

Classification Method:- This is a simple, widely used method. This method of job
evaluation was made popular by the U.S. Civil Service Commission. In the ranking
system there is no re-determined yardstick of values. In the job grading approach
there is one such yardstick constituting of job classes or grades. Jobs are measured
as whole jobs. Under this method job grades or classes are established by an
authorized body or committee appointed for this purpose.

Factors Comparison Method:- This is a combination of both rating and point rating
methods. It means rates jobs by comparing them and makes analysis by breaking
jobs into compensable factors. This system is usually used to evaluate white collar,
professional and managerial positions
Point Rating Method:- This is most widely used system of job evaluation. The
method evaluates the compensable factors of each job. It involves a more detailed,
quantitative and analytical approach to the measurement of job work. Under this
method jobs are broke down based on various identifiable factors such as skill, effort,
training, knowledge, hazards, and responsibilities and so on. Thereafter, points are
allocated to each of these factors. Weights are given to factors depending on their
importance to perform the job. Points so allocated to various factors of a job are then
summed. Then, the jobs with similar total of points are placed in similar pay grades.

Q18 what is merit rating what are benefits of merit rating?

 Merit rating is the process of rating the employees for their jobs in the
organization. In the organization, equipment and machines are evaluated that
whether they are meeting the requirements of the jobs to perform or not.
 Similarly, to check whether employees are meeting the requirement of the job is
done by merit rating. Merit rating is the assessment of performance of the worker
and his utility to the organization. Merit rating evaluates the worthiness of
employee to the job. In other words, how the employee is meeting the
requirements of the job. Job evaluation is carried in order to evaluate the job, while
merit rating evaluates the employee.

 Benefits of Merit Rating:

1. For rewards and promotions of employee

2. To measure the potential of the employee

3. To motivate the employee for better performance

4. To analyze the strengths and weakness of employee

5. To identify whether training is needed or not by the employee

Q19 What are the different methods of merit rating?

 Following are the different methods for merit ranking

1. Ranking method
2 Peer Comparison method
3. Check list method
4. Scale Plan
5. Forced Choice method

1. Ranking Method: In this method, employees are assigned in rank from best to
worst based on their performance. The rank may be given on the basis whether they
have done the job satisfactorily or not. This method is very easy and simplest
method. Although this method is easy and simplest, it is having following drawbacks
Ranking may be biased. Since ranking is subjective, it depends on person to person
This method is not able to highlight the strengths and weakness of the employee.

2. Peer Comparison method: This method is applicable only to small

organizations. As the name of the method implies, employees are compared with
their colleagues. Generally comparison between the employees is done on the basis
of their performance. Two peers are compared with each other for taking the decision
who is better. Then each employee is considered with the others.
This method has also drawback of subjective and biases same as of previous method.
Also, when the number of employees is large, it is lengthy and time consuming
process.

3. Check list method: In this method, list of questions related to important aspects
of employee performance for the assigned job is prepared. It has option of selecting
"YES or "NO". The evaluator has to tick the appropriate option for the employee.
This Method is easy for comparing the employee's performance as well as peer
comparison

4. Scale Plan: This method is very common method for measuring the performance
of the employee in the organization. Employee is rated on the basis of developed
scale. The scale plan may be in terms of percentage (20%, 40%.., 100%) or
descriptive (Poor, Fair, Good, Excellent) or linker scale (1, 2, 3, 4, 5) or alphabetical
scale (A, B,
C, D or E). Measurement of employee is done by selecting the appropriate scale for
the performance of the employee. Different categories of employees are high grade,
 average grade, low grade, above average grade and worst grade. Based on these
employees level are identified and persons are evaluated.

5. Forced Choice Method: This method is providing the options for selecting
the predefined choices available to the evacuator. The selected statement
describes the particular behaviour of the employee in that particular
parameter. Since this method is forcing the rater (or evaluator) to check only
one choice, this method is called forced choice method. This method does not
give any chance to rater for explaining the behaviour in his own words. This
method is very popular for rating the lower cadre of the staff.

Q20 What are the objectives of industrial legislation? Explain factory act
1948.
 Wage Incentive Plans
 Apart from wages paid to workers, in order to motivate the productivity,
organizations are offering them to earn higher returns based on their superior
efforts compared to others. Here, the condition is that the standard of product is to
be maintained. So, these offers of earning high returns are termed as wage
incentive plans. Wage incentive plans may be financial or non-financial. In
financial incentive plans workers are paid in monetary terms. In non-financial
incentive plans, incentives are paid in terms of gifts, discount coupons, leaves with
pay, housing facility, transportation facility, medical facility, education to their
worker, scholarships for higher education etc., are included. All these plans vary
from organizations to organizations.
 Following are various basic incentive plans which are widely accepted and applied
in various organizations. These can be classified in three categories as discussed
below:

a. Different piece rate plans (for individuals):

1) Taylor's Differential Piece Rate System
2) Merrick's Differential Piece Rate System
3) Gantt system
b. Premium bonus plans (for individuals):
1) Halsey Incentive system
2) Rowan's Plan
3) Bedaux Point system
4) Emersions Efficiency plan
c. Group incentive plans
1) Profit sharing scheme
Q21 What is inspection and what are its objectives? What are
different types of inspections.
 The basic aim behind inspection is to ensure the quality of the product. Although,
inspection cannot produce quality products but it helps in maintaining the quality
products.

 Objectives of Inspection

 From the above discussion of various functions performed by inspection and

types of inspections, we can summarize the objectives of inspection as follows:

(1) Trace the problem of defective raw materials and hence saving of labour hours
and skills on defective part production.

(2) Removal of defective semi-finished products.

(3) Separate out the defective products at the final stage and ensure quality of
products.

(4) Find out the causes of defective products at intermediate stages and eliminating
them.

(5) Helps in developing the reputation of the company.

(6) Finally, non-defective products help in achieving higher customer satisfaction.

 Types of Inspection

Types of inspection vary from product to product in order to confirm the quality of
The product. Following are the different types of inspection in most of the cases:

(1) Raw Material Inspection

(2) Tool and Machine Inspection
(3) Patrolling Inspection
(4) Key point Inspection
(5) Final Inspection
(6) Sample Inspection
(7) Inspection for the product for its Application
(1) Raw Material Inspection: First step to prevent the defective product
manufacturing is to inspect the raw material. If the input material is having defect,
than it is not possible to think about quality products. So, raw material inspection is
basic need for defect free product. Although, when input components are larger in
numbers and small in size, it is difficulty to inspect each and every component.
Sampling inspection is to be carried out under such condition.

(2) Tool and Machine Inspection: Problematic tools and machines is the second
reason for the defective product. If the tools are incompatible for the requirement for
the process, it is not possible to have quality product. For checking tools and
machine, generally periodical maintenance is followed. For automatic production
system, the single piece is checked after production in order to inspect the tool and
machine.

(3) Patrolling Inspection: It is random inspection on the shop floor. Inspector walks
in the shop floor and checks sample of the product by measurement and other visual
inspection. If there is any problem, it can be rectified at the shop floor only. So, time
can be saved as well as labour. This inspection is very effective for the assembly
type product. It is also termed as floor inspection.

(4) Key point Inspection: This inspection is done in order to allow the processed
job for the next stage. Depending on the products, critical stages are defined and at
every stage, necessary testing and inspection is done. This kind of stage inspection
helps in order to stop the error to propagate in the next stage. So, for every product
key point inspection is necessary.

(5) Final Inspection: Once the product is finally manufactured, passing through all
key point inspection, it is required to check for the performance. Necessary
destructive and non-destructive tests are being performed on the product in order to
check its ability of functioning as per requirement. This prevents the defective
product to go into the market.

(6) Sample Inspection: When the size of the product is small such as washers,
screws, nuts etc., it is not possible to inspect each and every product. For such kind
of product certain percentage from lot is inspected. Based on the results of the
samples a whole lot is judged for acceptance or rejection Sample inspection follows
to take a sample from the lot and checking for the size and specification. Sample
inspection is generally carried out where batch production is predominant.
(7) Inspection for the product for its Application: This type of inspection is done
when the product is introduced in the market for the first time. This testing is crucial
in order have customer satisfaction. Failure of product to meet the need of customers
for desired application requires further improvement in the design or process state.

Q22 Write short mote on six sigma.

 Six Sigma (o) is a quality control tool Sigma is Greek letter, which is used to
represent standard deviation. In six sigma methodology, use of previous available
data is done in order to carry out quality control. Generally it is assumed that the
quality curve is binomial distribution. Based on the mean value of the data, range
of sigma is defined as given in the table.
 Limits for Normal Distribution Curve Specification Limits Table shows the last
row for six sigma. It indicates that, when six sigma is implemented, only 3.4
defects are allowed in one million productions. The main aim of six sigma is to
produce defect free products and satisfies the customer. It also reduces the cost of
production as well as scrap of the products.

 Following are the benefits of six sigma implementation:

(1) Defects are eliminated

(2) Production and development costs are reduced
(3) Cycle time and inventory levels are reduced
(4) Profit margin and customer satisfaction is improve

Q23 write short note on quality control.

 Quality is a comparative term and interpretation of quality changes from person

to person depending upon the use of the product. In general terminology, quality
is related to the end user of the product.

A product is said to be qualitative, if it satisfies following characteristics:

1. It meets the requirements of end users.
2. Product must show desired performance level.
3. The use of product must be safe.
4. Also, product should be reliable, easy to handle, store.
5. Product should give satisfaction to the user as per expectation.

 Quality Control
 As discussed in the previous section, the quality is dependent on number of
parameters. So, it is necessary to ensure that quality is maintained at each end
every stage of product development. The tool containing various activities which
ensures the quality each and every stage of product is sustained is called quality
control. As per IS0 9000 quality control is defined as “a part of quality
management focused on fulfilling quality requirements”. So, quality control is
procedure intended to ensure that a manufactures product abide to a defined set
of quality criteria and meets the requirements of the customer.

 Objectives of QC:-

1. To develop a standard norms at each and every stage of production development

in order to ensure the product quality.

2. To ensure that developed system which produces economical product.

3. To locate and identify the faults at every stage of production development.

4. Rectification action and setting up of system which causes the faults in the
products.

5. To ensure that defective products do not reach to the market.

 Advantages of QC:-

1. Customer satisfaction can be improved.

2. Inspection cost can be reduced significantly.

3. Rejection rate of the products can be achieved. So, wastage of the product can be
eliminated.

4. Qualitative product improves reputation and hence sales can be increased.

5. Overall product cost can be reduced.

Q24 explain different types of control charts.
(1) p charts and np charts

P is defined as the fraction defective. It is the ratio of number of defective units in

each lot inspection to the number of units in the lot, while np charts is used for
number of defective in a sample. It is n times p chart.

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑢𝑛𝑖𝑡𝑠 𝑖𝑛 𝑒𝑎𝑐ℎ 𝑙𝑜𝑡 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑒𝑑

Mathematically, p =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑙𝑜𝑡

Control limits for p charts:-

3 ̅̅̅̅̅̅̅̅̅̅
𝑝(1−𝑝̅ )
Upper control limit, 𝑈𝐶𝐿𝑝 = 𝑝̅ + √
𝑛

3 𝑝̅ (1−𝑝̅ )
Lower control limit, 𝐿𝐶𝐿𝑝 = 𝑝̅ - √
𝑛

Control limits for np charts:-

3
Upper control limits, 𝑈𝐶𝐿𝑛𝑝 = n𝑝̅ + √𝑛𝑝̅ (1 − 𝑝̅ )
3
̅̅̅̅̅̅̅̅̅̅̅
Lower control limits, 𝐿𝐶𝐿𝑛𝑝 = n𝑝̅ - √𝑛𝑝(1 − 𝑝̅ )

(2) C charts and U charts

C – Chart id the chart drawn for number of defects per unit. Per unit can be no. 0f
products from one machine or one complete unit. C – Chart is to be calculated. So,
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠 𝑖𝑛 𝑎𝑙𝑙 𝑠𝑎𝑚𝑝𝑙𝑒𝑠
Mathematically, 𝑐̅ =
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑎𝑚𝑝𝑙𝑒𝑠 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑒𝑑

Upper control limit, 𝑈𝐶𝐿𝑐 = 𝐶̅ + √𝑐̅

3

3
Lower control limit, 𝐿𝐶𝐿𝑐 = 𝑐̅ − √𝑐̅
U chart is used when the sample size varies from sample to sample.
𝑐 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡 𝑖𝑛 𝑎 𝑠𝑎𝑚𝑝𝑙𝑒
U= =
𝑛 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑖𝑛 𝑎 𝑠𝑎𝑚𝑝𝑙𝑒

3 𝑢
Upper control limit, 𝑈𝐶𝐿𝑢 = u + √
𝑛

3 𝑢
Lower control limit, 𝐿𝐶𝐿𝑢 = u - √
𝑛

Q25. Explain different sampling plan and write short note on OC

curve.
 before understanding the sampling plans, it is necessary to understand certain
quality indies:

(1) Acceptance quality level (AQL):

(2) Rejection quality level (RQL):

(3) Indifference quality level (IQL):

(4) Average outing quality (AOQ):

(1) single sampling plan

 Suppose that there is N number of products in a given lot. From that n numbers
of samples are drawn from that lot. Based on statistical data analysis,
acceptance number ‘A’ is fixed. If the number of defects found in the sampling
does not exceed acceptance number ‘A’, then the lot is accepted.

(2) Double sampling plan

 In case of double sampling plan, two samples of size n1 and n2 is selected
from lot size N1 and N2. Suppose that A1 is the acceptance level of first
sample and A2 is the acceptance level of both samples combined.
 (3) Multiple sampling
 As the name suggest, more than two samples of stated size are taken for taking
any decision of acceptance or rejection of the lot.

 OC Curve:-
 Operating characteristic curve is a picture of sampling plan. OC curve is the curve
of probability of accepting the shipments of % non-confirming units. When any
products is manufactured, there are two probabilities: first one is for manufacturer
that whether the manufactured product is having satisfactory quality or not second
one for buyer that whether the product bought product will satisfy his needs or
not. So, both suffer from risks and these risks are of two types: manufacturer’s
risk means the risk of rejection to the manufacturer when he manufactures the
product. On the other hand, consumer’s risk is purchased, the consumer has a risk
that the product may be defective which is called consumer’s risk.
 Ideally, there should be one limit of selecting the sample which is inspected by
acceptance sampling method. If the % of non-confirming items goes above certain
percentage then the whole lot should be rejected. Here up to 4% of non-confirming
units, whole lot is accepted i.e., the acceptance level is 100%. As the % of non-
confirming units, goes above 4% the whole lot is rejected. Such kind of OC curve
is called ideal OC curve.