Industrial Engineering

and
Quality Control
SUBJECT CODE:- 22657
Teaching scheme and Examination Scheme
Work Study
▪ Unit outcome ▪ Topics and Sub Topics
Industrial Engineering
▪ Definition:-
▪ According to Institute of Industrial Engineers industrial engineering is connected with
Design, Development, and Installation of integrated system of people material
equipment and energy.
▪ Industrial engineering can be defined as a planning, scheduling and control of
activity that transform input into finished goods and services

▪ Needs
▪ Industrial engineering support service for workers, supervisors, staff and management
▪ It helps the company to be competitive in market
▪ Industrial engineering helps to lower the cost for producing a quality product
▪ It helps to stabilize company in the business
▪ It helps in planning and producing the better product
▪ Because of industrial engineering company is in a position to satisfy the customer
and stakeholders need
Industrial Engineering
▪ Objective and scope :-
▪ The primary objective of industrial engineering art
▪ To Increase Productivity By Optimum Utilization Of Input Resources
▪ To Optimize Complex Processes And System By Eliminating Wastage Of Production Time
▪ To Improve Methods Of Operation
▪ To Control The Production Cost Developer Various Methods Of Cost Control And Value Addition
▪ To Develop An Efficient And Effective Operation Work Cycle
WORK STUDY
▪ Work study or work analysis is
the discipline of industrial
engineering that uses various
techniques to quantitatively
measure or estimate work to
increase the amount produced
from a given quantity of
resources by improving the use
of existing resources.
WORK STUDY
▪ Definition :-
▪ 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.
▪ Work study is also understood as a systematic objective and critical examination
of the factors affecting productivity for the purpose of improvement. It make use
of techniques of method study and work measurement to ensure the best
possible use of human and material resources in carrying out 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 product/service
at minimum possible cost.
▪ To improve operational efficiency
Work Study

Method Study Work Measurement

- To simplify the job - Quantitatively measure work
- Develop better methods

The systematic recording and critical The application of techniques ,

examination of existing and deigned to establish the time for a
proposed ways of doing work as a qualified worker, to carry out a
means of developing and applying specified job at a defined level of
easier and more effective methods performance
and reducing costs.
 Objective Method Study

Improve in process To find the best way of Better workplace Better working Less fatigue to Better product quality
and procedures doing job layout conditions operators

Improvement in the Efficient and fast Greater job Reduction in waste Smooth streamlined
use of material, material handling satisfaction, Higher and Scrap flow of production and
Machines and standards of Safety Process
Manpower and Health
 Method study procedure

Select Record Examine Develop Define Install Maintain

The work to be All the relevant The recorded The most The new method The new method Under standard
studied under fact about facts critically practical, so that it can as standard practice by
the light of present and and question economical and always be practices regular routine
economics proposed a each details of effective method identified check.
technical and method by job considering considering all
human factor observation or in turn on the the circumstance
analysis purpose of
activity, where is
the sequence, in
which it is done,
the person who
is doing it and
the means by
which it is done
Method study procedure

Select • Work which can be studied with economic advantage

Record • All facts about job and operation

Examine • The facts critically (purpose, place, sequence, person) seek alternatives,
simplify, eliminate, combination or change

Develop • A record of an improved method under prevailing condition reexamine and

select the best method

Define • Method, procedure, layout, equipment working condition, material, quality

instruction

Install • The improved method plan arrange and implement

Maintain • Verify at regular interval that the improved method is used

Selection of work for method study

• Factors for selection of work for method study

1. Economic consideration
The cost is the usual basis for the selection of jobs for medical study
2. Technical consideration
As regards technical aspects matter study engineers should make sure that
adequate technical knowledge is available to carry out study and to overcome
manufacturing difficulties
3. Human reactions
It is quite difficult to predict employee attitude since the mental and emotional
reactions to investing and the chances of method should be anticipated
Recording techniques

1. Outline Process chart

2. Flow Process chart
A. Charts indicating process sequences I. Man type
II. Material type
III. Equipment type

1. Multiple activity chart

2. Simo chart
B. Charts using a time scale

1. Floor diagram
2. String diagram
C. Model and diagram indicating movement 3. Cycle graph
4. Corona cycle graph
5. Two- three dimensional models
Process chart
▪ A chart maybe diagram a picture or a graph which gives an overall view of the
process
▪ The chart representing process may be called as a process chart
▪ A process chart record graphically or diagrammatically in a sequence the operation
connected with the process
▪ This chart generally represented by symbols (symbols produce a better picture and
quick understanding of the facts )
▪ In process chart following five basic symbols are used to record different types of
activity

Operation Inspection Transport Storage Delay

Temporary Storage
 Process Chart

Symbol Activity Meaning

It indicate main step in a process method or procedure. usually the part, material
Operation our concern is modified or changed during the operation.
For example, cutting a bar on a power hacksaw filling facing

Inspection is an act of checking for correctness of quantity or quality of the item.

Inspection For example, gauging piston pin or checking the hardness of mild steel piece

This indicates a movement of worker , material, or equipment from a place to

Transport place.
For example, MS bar being sent from store to machine shop
delay occurs when something stops the process and product waits for the next
Delay or Temporary
event or operation
Storage For example, Power failure machine breakdown
It indicates when an object is intentionally written in a state or location and
Storage removal of the object required proper authorization
For example, finished goods are ready to sell / milling cutters laying on tool store

Operation Cum
For example, articles are being painted as the chain conveyor transport them
Transportation

Inspection Cum For example, powder milk beam is being weighted (inspection )as it is filled both
Operation event occurs simultaneously
1. Outline Process chart
▪ Sometimes in the initial stage of
the study an overall view of the
job under study can be
obtained by recording only the
key operations and inspection
without going into the whole
operation and inspection the
activities like delay movement
and storage such chart is
known as an outline process
chart
▪ E.g. Manufacturing and excel
and castle nut assembly
 Task:- Changing the refill of ball pen
Chart begins- unscrew the cap
charts end - screw the cap
Date: chartered by
1 Unscrew Cap
2 Unscrew Neck
3 Remove Old refill

4 Insert New Refill

5 screw Neck
1 Check if ball pen writes
6 screw Cap

Symbol
Summary
Frequency 6 1
 Outline Process Chart
Task:- Replacement of punctured tyre
Chart begins-
Charts end –
Date: _________Chartered by:-______

1 Unscrew Cap
2 Unscrew Neck
3 Remove Old refill

4 Insert New Refill

5 screw Neck

1 Check if ball pen writes

6 screw Cap

Symbol
Summary
Frequency
2. Flow process chart
▪ a flow process chart is a detailed version of outline process chart and it
required all the events
▪ flow process chart is defined as a graphical representation of all Operations,
Inspection, Transportation, Delays and Storage occurring during the process
or a procedure which includes information such as the time required,
quantity and distance moved etc.
▪ 3 types of flow process chart

Man type Material type Machine and

equipment type
Material Type
Machine Type
Two Hand Process Chart
Two Hand Process Chart
 1 Multiple Activity Chart
• Where a number of workers work in a
group or an individual operator handles 2
or more machines, their activities have to
be coordinated to get proper result
• Multiple activity chart records
simultaneously the activities of all the
workers and machine on a common time
scale and shows the interrelation between
them
• application
• plant repair and maintenance work
• construction jobs
• planning teamwork
Time
(Min)
1
2
3
4
5
6
7
8
9
10
11
12
2 Simo Chart
• Simo Chart Simultaneous motion
cycle chart
• It isa recording technique for micro
motion study
• It is an extremely detailed left and
right-hand operation chart
• it shows on a common time scale
Simultaneous minute movement
(therbligs) performed by 2 hands of
operator.
2 Simo Chart
3 MTM (Method Time Measurement)
▪ Search on Google…..
Models and Diagram
1 FLOW Diagram
2 String Diagram
3 Cycle Graph
4 Chrono Cycle Graph
5. Templates and Models
6. 3 D Models
7. Travel Chart
1.4.4 Micro Motion Study
▪ Micromotion study means the study of small motions known as a “Therbligs.”
▪ Each human activity is supposed to be divided into these small moments
▪ The purpose of such study is to find for a worker best pattern of movement
which involved less efforts less time and less fatigue to complete the task
▪ Micromotion study involve taking motion picture of an activity by camera
while being performed by an operator with timing device.
▪ Later on the film is studied by the running it slowly through a projector and
frame by frame analysis is carried out.
▪
1.4.4 Micro Motion Study

▪ Steps
▪ filming the job being performed with 16 MP movie camera the
range of speed is 1 to 64 frames per second
▪ micrometer or wink counter is a timing device kept in the field of
view while the filming
▪ timing can be read in a winks
▪ One wing 1 Winks = 1/2000 of a minute
▪ Analysis of the data from the field which includes selection a
typical work cycle from among the film cycle.
▪ recording of data done by using SIMO chart.
Therbligs
Therbligs
Therbligs
Workplace Layout
▪ Good workplace layout and productivity are closely related to each other. A
comfortable workplace keeps workers more satisfied. Bad working conditions
always result in poor productivity.
▪ Therefore, while designing the layout general principles and workplace layout
should be taken into consideration. These are :
▪ Fig. shows the normal and maximum working area
 Workplace Layout
1. Materials and tools should be located within the normal working area and as close and in
front of the operator as possible.
2. Anything kept beyond the maximum working area will make movement of the trunk and
increase fatigue.
3. Materials and tools should be located in the order in which they are used in assembly.
4. Workplace must be clean and well pointed- As cleanliness effects worker's efficiency.
5. Workplace must be properly illuminated so as to avoid eye strain.
6. Try to minimize the intensity of noise as possible because reduction in noise results in the
increase of efficiency.
7. Height of the chair and the work bench should be arranged in a way that permits
comfortable work posture.
8. From design point of view, man-machine must be considered as a single unit, so that
man can handle the machine with easiness and maximum comfort.
9. Worker should be able to operate levers and handles without changing body position.
10. Workplace should be free from the presence of harmful elements like heat, smoke, dust,
excess humidity, vibrations etc
1.5 Work Measurement
▪ Work measurement is also called by the name "Time study". Work
measurement involves assessment of time taken to do a job or method.
▪ Work measurement technique finds the time required to do a job by a
qualified operator working at a standard pace and using standard method.
▪ The time thus calculated is known as standard time.
▪ The method to do the job is normally standardized by using method study
procedure before carrying out work measurement
▪ Definition
Work measurement is defined as the application of techniques designed to establish
the time for a qualified worker to carry out a specified job at a defined level of
performance.
1.5.2 Work Measurement- Objectives
1. To determine the standard time for various operations this helps in fixing
wages and incentives.
2. To estimate cost of product accurately.
3. Planning and production control.
4. To achieve the delivery dates by assessment of accurate time for
completion of order.
5. To find out how many machines an operator can run with the help of man
machine chart.
6. To balance the work among the group of workers with the help of multiple
activity chart.
7. To identify standard worker.
8. To train new employees.
 1.5.3 Basic Procedure for Work Measurement

Select Record Examine Measure Compile Define

The work to be All the information The recorded data The time required to The standard time Precisely the series
studied and available about the and the detailed complete each for the operation or of activities and
determine me job, the operator and breakdown critically element using the work cycle. Add the method of operation
objectives of the the working to ensure that most suitable work suitable allowances for which the time
study. conditions. effective method and measurement to compensate for has been complied
Breakdown the job motions are being technique and fatigue, personal and issue
into elements. used calculate the time needs etc. the time standard
required to complete for the activities and
the work cycle which methods specified.
is known as basic
time
 Method study procedure

Select Obtain / Define Measure Extend Determine Compute

Record

The work to be All the relevant The recorded The most The new method The new method Under standard
studied under fact about facts critically practical, so that it can as standard practice by
the light of present and and question economical and always be practices regular routine
economics proposed a each details of effective method identified check.
technical and method by job considering considering all
human factor observation or in turn on the the circumstance
analysis purpose of
activity, where is
the sequence, in
which it is done,
the person who
is doing it and
the means by
which it is done
1.5.4 Time Study
Definition
▪ Time study is a work measurement technique for recording the times of performing a certain
specific job or its elements carried out under specified conditions, and for analyzing the data
so as to obtain the time necessary for an operator to carry it out at a defined rate of
performance.
▪ Time study is a technique for determining as accurately as possible from a limited number of
operations, the time necessary to carry out a given activity at a defined standard of
performance.
The following are the steps in making a time study :
1. Find the observed time for given task.
2. Apply a rating factor and find the normal time.
3. Add allowances for rest etc., and find the compiled time or standard time.
▪ In performing a time study, industrial engineers time the effort required to perform a defined task.
While it may sound simple, this is a complex process that requires special training and
experience.
▪ Time study is the application of work measurement technique to establish time for a qualified
worker to carry out a specified task under specified conditions and at the defined a level of
performance.
Uses of time study Procedure of time study
1. Determining schedules and planning Procedure for conducting the time study is
as follows:
work.
1. Secure and record information about the
2. Determining standard costs and as an operation and operator being studied.
aid in preparing budgets.
2. Divide the operation into elements and
record a complete description of the
3. Estimating the cost of a product before method.
manufacturing it
3. Observe and record the time taken by the
4. Determining machine effectiveness, the operator.
number of machines which one person 4. Determine the number of cycles to be
can operate. timed.

5. Determining time standards to be used 5. Rate the operator's performance.

as a basis for the payment of a wage 6. Check to make certain that a sufficient
incentive to direct labor and indirect number of cycles have been timed.
labor. 7. Determine the allowances.
6. Determining time standards to be used 8. Determine the time standard for the
as a basis for labor cost control. operation.
1.5.5 Time Study Equipment's
Basic time study equipment required to make the time study are : Time study equipment
1. A stopwatch
2. A study board
3. Time study forms

Tools of stopwatch time study

The tools of stopwatch time study are important to know before we get into the technique itself.
1. Stopwatches
(a) Continuous
(b) Snapback
(c) Three-watch
(d) Methods time measurement
(e) Digital
(f) Computer
2. Boards for holding watches and paper
3. Videotape recorders
4. Forms
1. Stop watch 2. Time study board 3. Time study form

4. Motion picture camera 5. Videotape recorder 6. Time study machine

1.5.6 Applications of Time Study
▪ For checking time standards obtained by other methods.
▪ For timing repetitive operations.
▪ For planning and scheduling work.
▪ For determining standard costs which helps in preparing budgets.
▪ To estimate cost of product before manufacturing it
▪ To determine effectiveness of machine.
▪ To determine time standards [Link] used as a basis for the wage payment
▪ To determine time standards to be used as a basis for labour cost control.
1.5.7 Standard Time
▪ Definition of Standard time
▪ Standard time is the time allowed to an operator to carry out a specified task under specified
conditions and at the defined level of performance.
▪ Standard time or allowed time is the total time in which a job should be completed at standard
performance. It is the sum of normal time (basic time) and allowances. Policy allowance is not
included.

▪ Definition of Basic time

▪ Basic time or normal time is the time taken by an operator of standard performance (rating of
100). An operator, whose work is observed, may be a slow or a fast worker. His rating may be
less than 100 or above 100. The standard rating is taken as 100.

▪ Rating is the measure of efficiency of a worker. Rating factor is determined by comparing

actual speed of worker with the speed of a qualified worker.
Rating of the observed worker
Rating factor =
Rating of qualified worker (Standard rating)

Normal time (Basic time) = Observed time x Rating factor

Operator Rating
Normal time (Basic time) = Observed Time x
Standard rating
▪ The basic constituents of standard time therefore are :
(i) Normal time or basic time
(ii) Compensation for the difference in operative pace of performance and standard performance
(iii) Relaxation allowance
(iv) Interference and contingency allowance
(v) Policy allowance

▪ A time study engineer observes and calculates time for the operation considering various
allowances. This is nothing but standard time. Once the standard time is known the total
production time can be calculated. Also the performance rating of the worker is calculated. This
helps in deciding the productivity and hence, for improving the productivity
1.5.8 Calculation of Standard Time
▪ The standard time for an operation will be the sum of the standard times for all the elements of which it
is made up.

▪ The standard time is expressed in standard minutes or standard hours.

▪ Standard time is the total time in which a job should be completed at standard performance.

Observed time x Observed rating

▪ Standard time = Basic time + Allowances Where, Basic time =
Standard rating
RF P F D O.A

Basic Time Allowance

R.F. = Rating factor D = Delay allowance

P = Personal allowance OA = Other allowances
F = Fatigue allowance
1.5.9 Allowances
▪ Allowance is an amount of time added to the normal time to provide personal
needs, unavoidable delays and fatigue of the operator.
▪ Allowances when added to the normal time, it results in standard time.
▪ During the typical eight hour workday people do not work continuously. They
stop working entirely due to various causes such as.
▪ Attending to personal needs
▪ Resting to overcome fatigue
▪ Talking to supervisors or management
▪ Taking meal breaks, snacks etc.
▪ Waiting for supervisor's assistance
▪ Waiting for instructions, parts, materials, equipment's so on ……
 Types of allowances
1. Personal allowance (P factor)
2. Relaxation or fatigue allowance (R or F factor)
3. Delay allowance (D factor)
4. Other allowances
a) Contingency allowances .
b) Policy allowances.
c) Machine interference allowances.
Types of allowances
Personal allowance (P factor)
▪ This allowance is present in any work environment In order to satisfy personal needs, the
allowance provided is known as personal allowance.
5% addition to basic time are used to allow for personal needs.
▪ e.g. Getting glass of water, washing hands, going to toilets etc.

Relaxation or fatigue allowance (R or F factor)

▪ Fatigue, rest or relaxation allowance is given to a worker to overcome fatigue incurred by the
worker because excessive fatigue affects badly the performance of a worker.
▪ Fatigue is the result of:
▪ Unhealthy working conditions
▪ Physical exertion
▪ Inconvenient positions while working
▪ Concentration etc.

Generally, fatigue allowance added from 5% to 50% to the normal time for light to heavy tasks
Types of allowances
Delay allowance (D factor)

▪ Throughout the workday, many interruptions to the work cycle occur, such as:
▪ Waiting for parts, materials or tools
▪ Receiving instructions from supervisors
▪ Waiting for a crane to clear work area
▪ Answering co-worker's questions (work-related)

▪ These are the delays which may not Decompensated in any way or for which management can be
held responsible.

▪ The D factor ranges from 1 to 5% to the basic time.

 Types of allowances
Other allowances
▪ Sometimes, it is necessary to include additional percentage allowances over and above
those used to compensate for personal needs, fatigue and unavoidable delays. There are:

Contingency allowances Policy allowances Machine interference allowances

▪ There are often used to cover short ▪ A policy allowance is an increment ▪ Sometimes an operator is assigned
periods of extra work that are largely other than bonus increment applied to attend to two or more machines
unpredictable and not a part of to standard time to provide a that are running simultaneously.
measured task such as: satisfactory level of earning for a Sooner or later one or more
specified level of performance. machines will be idle while the
operator attends to another
machine. This will produce a delay
that is not normally covered by other
allowances

▪ Correcting the material that are not to ▪ It is an addition to standard time often ▪ This will cause the operator to appear to
specification, used to modify earning opportunities work below standard performance.
▪ Additional checking or inspection. within incentive programs. ▪ To compensate for this, a machine
▪ Additional work caused by the ▪ It is allowed as a percentage of interference allowance may be applied
malfunction of equipment standard time. as a percentage of standard time
▪ a particular activity on the shop floor consists of 3 elements that calculate the
Standard Time for the activity. The various allowances are given as a
percentage of the normal time.

Element I II III
observe time in minute 1.10 0.20 0.50
rating factor in percentage 80 90 85
Allowances
relaxation 10 11 12
Delay 4 3 2
Personal 5 8 6
▪ For element I
▪ step number 1
𝑂𝑏𝑒𝑠𝑒𝑟𝑣𝑒 𝑇𝑖𝑚𝑒 𝑥 𝑅𝑎𝑡𝑖𝑛𝑔
Basi𝑐 𝑇𝑖𝑚𝑒 = 100
1.10𝑥 80
Basi𝑐 𝑇𝑖𝑚𝑒 = = 0.88 𝑚𝑖𝑛
100
Total alarms
𝑇𝑜𝑡𝑎𝑙 𝐴𝑙𝑙𝑜𝑤𝑛𝑎𝑐𝑒 = ( Personal allowance + delay allowance relaxation allowance )