TOPIC 2:

METHOD STUDY
(PART IV)
4. Develop

◼ During critical analysis of the task being

study, ideas on how to improve it
emerges.

◼ The next step will be to develop these

ideas into feasible solutions and select
the optimum one.
BASIC PROCEDURE/APPROACH FOR METHOD STUDY
i. Select

ii. Record
iii. Examine

iv. Develop

v. Evaluate

vi. Define
vii. Install
viii. Maintain
4.1 Factors to be considered in solution development:

i. Material flow and material handling.

▪ Improve layout.
▪ Choose the right material handling
equipment.
▪ Minimize material handling – non
productive activity.
 Different types of material handling equipment

Conveyor Trolley Hoist

Skid Fork lift / industrial truck Crane

 Possible method of handling an object

Trolley Crane & Hoist

Conveyors Robot

Truck
ii. Workers movement in the work place
◼ Minimize or eliminate ineffective movement.

iii. Method and movement in the workplace

◼ Simplify method of doing work.
◼ Minimize ineffective movement.
4.2 Principles that may be used:
i. Principles of motion economy.
ii. Poka Yoke (Mistake proofing method).
iii. SMED (Single Minute Exchange of Die)
iv. DFMA (Design For Manufacture & Assembly).
v. Ergonomics.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
 Category 1. The use of the human body
a) Both hands should begin as well as complete their motions at
the same time.

b) Both hands should not be idle at the same time except during
rest periods.

c) Motions of the arms should be made in opposite &

symmetrical directions & should be made simultaneously.
Symmetrical motion balance each other
and reduces the shock on the body and
requires less mental and physical effort.
d) Motions should be confined to the lowest degree /
classification as possible to perform the work satisfactorily.

◼ Material and tools should be located as

close as possible to where it is used.
◼ Hand motions should be a short as the
work permits.
◼ Lowest classification usually need least
time and effort.
e) Momentum should be used wherever possible but should be
reduced to a minimum if it must be overcome by muscular
effort.
The motion of worker need to be
so arrange that the forcible stroke
is delivered when it reaches its
greatest momentum.

Momentum = mass X velocity.

f) Smooth continuous curved hand
motions are better to straight line
motions that involve sudden and
sharp changes in direction.

◼ Abrupt changes in direction are time

consuming and cause fatigue.
g) Ballistic movements are faster, easier and more
accurate than restricted or controlled movements.

◼ Less fatiguing as muscle only contract at

the beginning of the movement and are
relaxed during the rest of the movement.

◼ Eg: Swinging a hammer in driving a nail.

h) Work should be arranged to permit an easy and natural
rhythm wherever possible.

◼ Rhythm – regular repetition of a certain

cycle of motions.
◼ Uniformity, ease and even speed of work
are assisted by proper arrangement of
workplace, tools and materials.
◼ Less mental effort is required.
i) Work should be arranged such that eye motion is limited to
one comfortable area without requiring frequent focus change.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
Category 2. The arrangement of the work place

1. There should be a definite and fixed

place for all tools and materials.

◼ This encourage habit formation.

◼ Able to perform operation with least
conscious mental direction.
◼ No need for eyes to direct the hands.
2. Tools and material should be placed
first to reduce search activity.

◼ Preparation and initial set up can

eliminate delay and searching for
tools and material later on.
3. Gravity feed, box or container should be
used to deliver material.

◼ Gravity is free, use it.

4. Tool and material should be placed within the maximum
working area and as close as possible to the worker.

Forearm-only (preferable) and full-arm (satisfactory) reach limits for men and women in
working areas shown in the horizontal and vertical planes.
5. Material and tools should be
located to permit the best
sequence of motions.

◼ The material required at the start

of a cycle should be placed next
to the point of release of the
finished product (end of a cycle).

◼ Material should be arrange

according to sequence of task.
6. Drop deliveries or ejectors
should be used.

◼ Use gravity.

◼ Free the hands to do other

important activities.
7. Adequate illumination and good contrast should be
provided.

◼ Sufficient intensity for that particular task.

◼ Proper color and without glare.

◼ Light from the right direction.

 General lighting Localized-general lighting Local (or task)
lighting

Local (or task) lighting increases

Localized-general lighting uses light levels over the work and
General lighting provides fairly uniform
overhead fixtures in addition to immediate surroundings. Local
lighting. An example would be ceiling
ceiling fixtures to increase lighting lighting often allows the user to
fixtures that light up large areas.
levels for particular tasks. adjust and control lighting and
provides flexibility for each user.
8. Ergonomically designed chair and workplace should be used.

◼ Height of workplace and

chair should fit user.

◼ Should permit good

posture.

◼ Should allow user to vary

posture.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
Category 3. The design of tools and equipment

1. Hands should be free from all work that may be done

better with a jig, fixture or a foot-operated device.
Jig and Fixture
Electric punching press machine
2. Two or more tool should be combined.

◼ Eliminate the need to change tools each time a different

one is required.
Seat inside the car
3. Load should be distributed in accordance to the inherent
capacities of the fingers.

◼ The fingers have unequal inherent capacities for doing

work.
4. Handles of tools should be designed so as to allow as
much surface area of the hands to be in touch with it.

◼ The more surface area in touch with a handle, the

stronger and more comfortable the grip will be.
5. Levers,hand wheels, and other controls should be located
such that it can be manipulated with the least change in
body position and the greatest mechanical advantage.
Thank you