IENG-2008

Work Systems Analysis & Design

Weeks 4 & 5
 WORK STUDY
Work Study: The techniques of method study
and work measurement which are
employed to ensure the best possible use
of human and material resources in
carrying out a specified activity.
 WORK STUDY
A valuable tool for management since:
1. It is a means of raising the productive efficiency
(productivity) of a factory or operating unit by the
reorganisation of work, a method which normally
involves little or no capital expenditure on plant and
equipment
2. It is systematic, ensuring that no factor affecting the
efficiency of an operation is overlooked, whether in
analyzing existing work practices or developing the
new ones, and that all the facts about the operation
are available.
 WORK STUDY
A valuable tool for management since:
3. It is the most accurate means yet evolved of setting
standards of performance, on which the effective
planning and control of production depends
4. The savings resulting from properly applied work
study start at once and continue as long as the
operation continues in the improved form
 WORK STUDY
A valuable tool for management since:
5. It is a tool which can be applied everywhere; can be
used with success wherever manual work is done or
plant is operated, not only in manufacturing shops,
but also in offices, stores, laboratories, and service
industries such as wholesale and retail distribution
and restaurants
6. It is the most penetrating tool of investigation
available to management, making it an excellent
weapon for starting an attack on the efficiency of any
organisation, since, in investigation of one set of
problems, the weaknesses of all the other functions
affecting it will gradually be laid bare
 WORK STUDY
Method Study: Systematic recording, analysis,
and critical examination of existing and
proposed ways of doing work and the
development and application of easier and
more effective methods.
Work measurement: Application of
techniques designed to establish the work
content of a specific task by determining
the time required for carrying it out at a
defined standard of performance by a
qualified worker.
 WORK STUDY
Basic procedure of Work Study:
1. SELECT the job or process to be studied (M.S. &
W.M.)
2. RECORD from DIRECT OBSERVATION everything
that happens, using the most suitable of the recording
techniques, so that the data will be in the most
convenient form to be analyzed (M.S. & W.M.)
3. EXAMINE the recorded facts critically and challenge
everything that is done, considering in turn: the
purpose of the activity; the place where it is
performed; the sequence in which it is done; the
person who is doing it; the means by which it is done
(M.S. & W.M.)
 WORK STUDY
Basic procedure of Work Study:
4. DEVELOP the most economic method of taking into
account all the circumstances (M.S.)
5. MEASURE the quantity of work involved in the
method selected and calculate a standard tim for its
performance (W.M.)
6. DEFINE the new method and the related time so that
it can always be identified (W.M.)
7. INSTALL the new method as agreed standard
practice with the time allowed (M.S.)
8. MAINTAIN the new standard by proper control
procedure (M.S.)
 WORK
STUDY

WORK
METHOD
MEASURE
STUDY
MENT

DEVELOP
Best Method
Under Prevailing
Circumstances

ALLOWED TIME
for the
Defined Method
DEFINE
INSTALL
MAINTAIN
that Method

HIGHER
PRODUC
TIVITY
 WORK
STUDY

WORK
METHOD MEASURE
STUDY MENT
to improve methods
of production

Select
work to be studied

Record
present method to limit of
detail economically justified using

OPERATION FLOW FILM

PROCESS PROCESS MOTION ANALYSIS
CHARTS CHARTS CHARTS CHARTS

Examine
the facts critically considering in turn
PURPOSE--PLACE--SEQUENCE--PERSON--MEANS
DEVELOP Best Method
Under PrevailingCircumstances
 WORK
MEASUREMENT
WORK to provide a
yardstick for
STUDY human effort

Select
work to be measured

Record
METHOD where necessary, effective and
STUDY ineffective time under existing conditions

Examine
in order to eliminate ineffective time
DEVELOP
Best Method Define
Under Prevailing method to be used
Circumstances Break Job Down into Elements
Measure
quantity of work involved in that method by

TIME ANALYTICAL
SYNTHESIS
STUDY ESTIMATING
Apply establihed times
Time and rate Of established as far as possible
elements element values Estimate normal times
Normalize
for others

Add rest allowances and determine

the total work content of the job

DEFINE
Work Unit Value
INSTALL Add other justifiable allowances
MAINTAIN and determine
that Method ALLOWED TIME for the Defined Method
 WORK
STUDY

WORK
METHOD
MEASURE
STUDY
MENT

DEVELOP
Best Method
Under Prevailing
Circumstances
ALLOWED TIME
for the
Defined Method
DEFINE
the new method
INSTALL
MAINTAIN
that Method

to achieve
to achieve Improved planning and
Improved Factory and control
workplace layout More efficient manning
Improved design of equipment of plant
Better working environment Reliable indices for
HIGHER
Reduction of fatique labour performance
result in improved use of PRODUC
Reliable Basis for
Land TIVITY
labour cost control
Material Sound incentive
Plant and Equipment schemes
Manpower
 Process Analysis

Product Process Analysis: Analysis centers on the flow of products. Most

appropriate when studying the way a product is made as it passes through various
processes.

Operator Process Analysis: Analysis centers on studying and improving the

movements of the operator. Most appropriate when studying the way an operator
moves when carrying out her/his work.

PROCESS Operator- Machine Analysis: Analysis centers on studying and

improving the combination of operator work and machine work. Most
ANALYSIS appropriate for discovering where standby time and idle time exists within
Joint
operator-machine combinations.
Process
Analysis Joint Operation Analysis: Analysis centers on studying and improving
the way several operators work together. Most appropriate for discovering
where standby time exists within such multi-operator situations.

Clerical Process Analysis: Analysis centers on studying and improving the way
office and administrative tasks are carried out. Most appropriate for discovering
delays or possibilities for mistakes in coveying information.
 Basic Symbols
No Step Symbol Meaning Example

Alters the shape or other

characteristics Drive nail
1 Operation of a material, semi- Drill hole
finished product, or Type letter
product

Changes the location of a

Move by truck,
material,semi-
2 Transportation hoist, elevator
finished product, or
Carrying
product

Bulk storage of raw

A scheduled accumulation of
3 Storage material, finished
materials, parts or products
product in warehouse

Material waiting to be
4 Delay D An unscheduled accumulation
of materials, parts or products
processed, worker
waiting for lift or raw
material

Measurement of amounts
Testing and visual inspection of Examine material for
materials, parts or products for quality and quantity,
5 Inspection
comparison with the specified read gauge, examine
amounts or standards to judge printed form
whether a discrepancy exists
CASE STUDY-OPERATION ANALYSIS- Dough Shaping Machine
CASE STUDY-MOVEMENT ANALYSIS- Die Changing
 METHOD STUDY
Selecting the Work to be Studied:
• Economic Considerations: “Will it pay to begin
a method study of this job?”, “Will it pay to
continue this study?”
– Bottlenecks
– Movement of materials over long distances
– Operations involving repetitive work
• Technical Considerations: Availability of
adequate technical knowledge
– Loading of unfired ware kilns in a pottery
– Machine tool used on a slow machine
 METHOD STUDY
Selecting the Work to be Studied:
• Human Reactions: Mental and emotional
reactions to investigation and changes of
method
– True objectives of the study
– Selecting unpopular jobs first
 METHOD STUDY
Flow Process Chart:
The chart for setting out the sequence of the flow
of work or of a product, or any part of it,
through the factory or department by recording
all the events under review, using the
appropriate symbols
– Bird’s eye view of what is being done
– Recording to be based on direct observation
– Neatness and accuracy counts
– Basic heading points to be recorded as well
 METHOD STUDY
Flow Process Chart:
Heading Information:
– Summary of distance, time, and (optional) cost of
labor & material)
Before concluding recording, ensure:
– Have the facts been correctly recorded ?
– Have any over-simplifying assumptions been made?
– Have all the factors contributing to the process been
recorded?
 METHOD STUDY
Examine Critically:
Sets of activities recorded:
1. Those in which something is actually happening
to the material or workpiece under
consideration (being worked upon, moved, or
examined)
a. MAKE READY Activities - prepare the material or
work piece and set it in position ready to be worked
on (Transport/Inspection)
b. DO operations – a change is made in the shape,
chemical composition or physical condition of the
material or workpiece (Operation)
 METHOD STUDY
Examine Critically:
Sets of activities recorded:
c. PUT AWAY Activities – work is moved aside from the
machine or workplace (Transport/Inspection)
2. Those in which it is not being touched, being
either in storage or at a standstill owing to a
delay (Storage/Delay)
DO operations – productive
Other activities - nonproductive
 METHOD STUDY
Examine Critically:
Examining the activities recorded through:
The PURPOSE for which
The PLACE at which
The SEQUENCE in which
The PERSON by whom
The MEANS by which
with the aim of
ELIMINATING
COMBINING
REARRANGING
SIMPLIFYING