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Work Measurement: Rodger Koppa, P.E., Ph.D. Industrial and Systems Engineering
Work Measurement: Rodger Koppa, P.E., Ph.D. Industrial and Systems Engineering
MEASUREMENT
Rodger Koppa, P.E., Ph.D.
Industrial and Systems
Engineering
Uses of Work Measurement
1. Compare efficiency of alternative methods
2. Balance work among team members
3. Optimize number of machines per operator
(e.g., in a work cell)
4. Establish basis for
• Production planning and control
• Layout
• Process planning
• JIT
More Uses
5. Pricing estimation
6. Standards for labor performance and
machine use for 1-5 and for incentives
7. Information for labor cost control –
enable standard costs to be fixed and
maintained
Basic Six Pack
SELECT what to study
RECORD that activity or operation
EXAMINE the recorded data and modify
procedures/task allocation/layout using Work
Study to get the best method
MEASURE quantity of work with respect to time
with the best method or ESTIMATE using
predetermined time data
COMPILE a standard time for activity, including
allowances
DEFINE activity and standard time
Work Measurement Techniques
1. Work Sampling
2. Structured Estimation
3. Time Study
4. Predetermined Motion Time
Standards (PMTS)
5. Standard Data Systems (SDS)
Technique 1: Work Sampling
Definition—Work Sampling
Work sampling is a method of finding the
percentage occurrence of a given activity
by statistical sampling and random
observations
Also known as:
Activity sampling
Ratio-delay study
Random observation
Snap-reading method
Observation ratio study
When to Use Work Sampling
A Machine allowance
m
Machine time
(automatic)
“significant” part of
cycle time
Allowance Example
Assembly of a framus
Cycle basic time is 10 min
PFD allowance is 10% (no definite breaks,
worker is free to go to restroom, water cooler)
Contingency allowance is 10% (junky equipment
up the line)
Machine allowance is 0 (hand and pneumatic
tools only in this operation)
Training allowance is 5% (high turnover)
Standard time = 10 x 1.25 = 12.5 min
Worker-Machine Standard Times
Some terminology:
Unrestricted work: hand/power tool work
where output affected by factors under
worker control during cycle. Person-
machine relationship
Restricted work: Machine does some to
most of work done, worker initiates,
terminates, but cannot change machine
part of cycle. Person-machine system
Basic Concepts
1. Machine maximum time—time machine available
during given period
2. Machine idle time—machine theoretically available, but
other factors preclude use
3. Machine ancillary time—machine out for cleaning,
setting, programming
4. Machine down time—machine out for breakdown,
maintenance, repair
5. Machine running time—time during which it is actually
running/producing (Trt = 1 – (2,3,4)
6. Machine running time standard—(2,3,4) minimized
3 Indices
1. Machine Utilization Index: Running Time
Avail Time
2. Machine Efficiency Index: RT Standard
RT
3. Machine Effective Utilization Index:
RT Standard
Avail Time
Approach to Improving Restricted
Work
Maximize 3 indices (approx. 1)
Do methods study with machine time in
cycle fixed
Worker does part of work in cycle while
machine stopped (“outside” work)
Worker does part of work while machine
does its thing (“inside” work)
What outside work could be shifted to
inside work, thus shortening cycle time?
Allowances in Restricted Work
Personal needs PN – based on total cycle time,
worker is at workplace even if he/she not
actually doing anything
Fatigue FA—based on time (inside/outside)
worker actually is doing something productive
Try to allocate during machine part of cycle
BUT consider whether machine can be left
unattended, if not “floaters” may be necessary
Most often, personal need times must be outside
cycle (cycle time too short to run to restroom!)
Fatigue Allowance (FA)
If 90 sec or more unoccupied time, charge
it to FA
If 30-90 sec unoccupied time, deduct 30
sec and multiple by 1.5
4 Basic Situations
1. All PN and FA taken outside cycle
2. PN outside, FA inside
3. PN and some FA outside, some FA
inside
4. PN and FA inside
Try to work DOWN this list to achieve # 4 by
method study
Unoccupied Time “Allowance”
On some person-machine systems worker is
unoccupied during the machine portion of a
cycle much more than on other systems
Should worker be paid the same when he/she is
working vs not working during cycle?
Paying same leads to perceived inequities in
pay between high-manual vs high-machine jobs
Pay rate may be different for “work” vs.
“unoccupied” time to compensate
Multiple Machines
1 worker may tend more than 1 machine
2 or more workers may tend 1 machine (e.g.,
power plant)
To study cycle, IE must do timelines for each
worker and each machine in cycle
“Load factor” = proportion of cycle time required
by worker to carry out necessary work during
machine process cycle
Reciprocal of Load Factor ~ Number of
machines worker “could” tend during cycle
Resources
Beside the WEB, consider these publications:
1. Groover, M.P. Work Systems and the Methods,
Measurement, and Management of Work
Pearson Prentice Hall, 2007
2. Kanawaty, G. (Ed) Introduction to Work Study
(4th Ed) International Labour Office, Geneva,
Switzerland, 1992
3. Mundell, M.E. and Danner, D.L. Motion and
Time Study: Improving Productivity (7th Ed)
Prentice Hall 1994