Method Study

• Method study, aims to achieve the better method of

doing work, and for this reason method study is
sometimes called Work Method Design.

Definition:
Method study can be defined as the procedure for
systematic recording, analysis and critical examination
of existing or proposed method of doing work for the
purpose of development and application of easier and
more effective method.
 Why method study is important ?
1. The improvement of processes and procedures.
2. The improvement of factory, shop and workplace layout.
3. The improvement of the design of plant and equipment.
4. Economy in human effort and the reduction of unnecessary
fatigue.
5. Improvements in the use of materials, machines and manpower.
6. The development of a better physical working environment.
7. Improvement of quality of the products.
 Method Study Procedure
The following general steps describe the procedure for
making a method study.

• Select the job – on which method study is to be applied.

• Obtain information and record.
• Examine the information critically.
• Develop the most practical, economical and effective
method by considering real limitations of the situation.
• Install the new method as standard practice.
• Maintain the standard practice by regular follow up.
 Selection of Job for Method
Study
Considerations may be given to the following factors while selecting a job for method study
,
1. Economic Factors :
If the economic importance of a job is small, it is not wise to start or continue a
long study. Priorities should be given to those types of job which offer greater
potential for cost reduction. Such jobs are easily identifiable
2. Technical Factors :
The method study engineer must have the necessary technical knowledge about
the job to be studied.
3. Human Factors :
Emotional reaction of the workers to the method study and changes in method
are important considerations.
 Information Collection and Recording
The accuracy of data about the method study problem is important for the
development of improved method. The following techniques are used for the
collection of information / data about the task under consideration.

1. Observations
2. Discussion
3. Records
4. Motion pictures or video films
Information Recording Techniques
There are three main types of information
recording techniques. These are,

1. Process Charts
2. Diagrams
3. Templates
 1. Process Charts
i)Those which are used to record a process sequence (i.e. series of events in the
order in which they occur) but do not depict the events to time scale.

Charts falling in this group are

1. Operation process chart / outline process chart
2. Flow process chart – (man / material / equipment type)
3. Operator chart (also called Two Handed Process Chart)

(ii) Those which record events in the sequence in which they occur on a time scale
so that the interaction of related events can be more easily studied. Charts falling
in this group are

4. Multiple activity chart (man – machine chart)

5. Simo chart (Simultaneous Motion Cycle Chart)
1.1 Operation process chart
Ex: Manufacturing of Electric bulb
Assembly of two plates with rivets
 1.2 Flow process chart – (man / material /
equipment type)
A flow process chart is used for recording greater detail than is possible in an
operation process chart. It is made for each component of an assembly rather
than for the whole assembly.

A flow process chart shows a complete process in terms of all the elements of
work. There are two main types of flow charts: man, material and machine
type . The product type records the details of the events that occur to a product
or material, while the operator flow chart details how a person performs an
operational sequence.

An important and valuable feature of this chart is its recording of non-

productive hidden costs, such as delays, temporary storages, unnecessary
inspections, and unnecessary long distances traveled. When the time spent on
these non productive activities is highlighted, analyst can take steps to
minimize it and thus reduce costs.
1. Man type : example
2. Material type
3. Machine type
 1.3 Operator chart
(Two Handed Process Chart)

Two-Handed Flow Process Chart, is a motion study where the study is done to
analyze the motions used by the worker in performing an activity.

In this chart the activities of a worker’s hands (or limbs) are recorded in their
relationship to one another.

A Two-Handed Process Flow Chart individually shows the movement of each

hand in a manual process. It is typically used for repetitive operation when
analyzing a manual assembly process, to help make it easier to perform.
 Format of Two handed process chart
Procedure :
 1.4 Multiple Activity Chart
(man – machine chart)
A Multiple activity chart is a form of process
chart recording the related sequence of work
of a number of operators and/or machines on
common time scale.
 Examples
1.
2.
 2. Diagrams
2.1 Flow Diagram
2.2 String Diagram
 Micro – Motion Study
Motion study is a technique of analyzing the body motions employed
in doing a task in order to eliminate or reduce ineffective movements
and facilitates effective movements. By using motion study and the
principles of motion economy the task is redesigned to be more
effective and less time consuming.

The Gilbreths pioneered the study of manual motions and developed

basic laws of motion economy that are still relevant today. They were
also responsible for the development of detailed motion picture
studies, termed as Micro Motion Studies, which are extremely useful
for analyzing highly repetitive manual operations. With the
improvement in technology, of course, video camera has replaced the
traditional motion picture film camera.
 Steps in Micro-Motion Study
1. Filming the operation to be studied
2. Analysis of data
3. Making recording of data

Taking the cine films @ 16 to 20 frames per second with motion picture
camera, developing the film and analyzing the film for micro motion study
had always been considered a costly affair. To save on the cost of
developing the film and the cost of film itself, a technique was used in
which camera took only 5 to 10 frames per minute. This saved on the time
of film analysis too.
Time is recorded in winks (1 Wink = 1/2000 of minute)
 Therbligs
On analysing the result of several motion studies conducted,
Gilbreths concluded that any work can be done by using a
combination of some or all of 17 basic motions, called
Therbligs (Gilbreth spelled backward).

These can be classified as effective therbligs and ineffective

therbligs. Effective therbligs take the work progress towards
completion. Attempts can be made to shorten them but they
cannot be eliminated. Ineffective therbligs do not advance the
progress of work and therefore attempts should be made to
eliminate them by applying the Principles of Motion Economy.
 Therbligs
1. Effective therbligs
2. Ineffective therbligs
 17 Therbligs
1. Transport empty (TE) – reach for an object
2. Grasp (G) – grasp an object
3. Transport loaded (TL) – move an object with
hand and arm
4. Hold (H) – hold an object
5. Release load (RL) – release control of an
object
6. Use (U) – manipulate a tool
 17 Therbligs (continued)
7. Pre-position (PP) – position object for next
operation
8. Position (P) – position object in defined location
9. Assemble (A) – join two parts
10.Disassemble (DA) – separate multiple parts that
were previously joined
11.Search (Sh) – attempt to find an object using
eyes or hand
 17 Therbligs (continued)
12. Select (St) – choose among several objects in a group
13. Plan (Pn) – decide on an action
14. Inspect (I) – determine quality of object
15. Unavoidable delay (UD) – waiting due to factors
beyond worker control
16. Avoidable delay (AD) – worker waiting
17. Rest (R) – resting to overcome fatigue
Classification of Therbligs
Effective therbligs: Ineffective therbligs:
• Transport empty • Hold
• Grasp • Pre-position
• Transport loaded • Position
• Search
• Release load
• Select
• Use
• Plan
• Assemble • Unavoidable delay
• Disassemble • Avoidable delay
• Inspect
• Rest
 SIMO Chart
(Simultaneous Motion Cycle Chart)

It is a graphic representation of an activity and shows the

sequence of the therbligs or group of therbligs
performed by body members of operator. It is drawn on
a common time scale. In other words, it is a two-hand
process chart drawn in terms of therbligs and with a time
scale.
Procedure :
Making the Simo Chart. A video film or a motion picture film is
shot of the operation as it is carried out by the operator. The film
is analyzed frame by frame. For the left hand, the sequence of
therbligs (or group of therbligs) with their time values are
recorded on the column corresponding to the left hand. The
symbols are added against the length of column representing the
duration of the group of therbligs. The procedure is repeated for
the right hand and other body members (if any) involved in
Uses of Simo
carrying out theChart :
operation.
From the analysis shown in chart about the motions of the two
hands (or other body members) involved in doing an operation,
inefficient motion pattern can be identified and any violation of
the principle of motion economy can be easily noticed. The
chart, therefore, helps in improving the method of doing an
operation so that balanced two-handed actions with coordinated
foot and eye motions can be achieved and ineffective motions
can be either reduced or eliminated. The result is a smoother,
 Cycle graph
These are the techniques of analyzing the paths of motion made
by an operator and were originally developed by the Gilbreths.
To make a cycle graph , a small electric bulb is attached to the
finger, hand, or any other part of the body whose motion is to be
recorded. By using still photography, the path of light of bulb (in
other words, that of the body member) as it moves through space
for one complete cycle is photographed. The working area is
kept relatively less illuminated while photograph is being taken.
More than one camera may be used in different planes to get
more details. After the film is developed, the resulting picture
(cycle graph) shows a permanent record of the motion pattern
employed in the form of a closed loop of white continuous line
with the working area in the background. A cycle graph does not
indicate the direction or speed of motion.
It can be used for,
 Chrono cycle graph
The chrono cycle graph is similar to the cycle graph, but the
power supply to the bulb is interrupted regularly by using an
electric circuit. The bulb is thus made to flash. The procedure for
taking photograph remains the same. The resulting picture
(chrono cycle graph), instead of showing continuous line of
motion pattern, shows short dashes of line spaced in proportion
to the speed of the body member photographed. Wide spacing
would represent fast moves while close spacing would represent
slow moves. The jumbling of dots at one point would indicate
fumbling or hesitation of the body member. A chrono cycle graph
can thus be used to study the motion pattern as well as to
compute velocity, acceleration and retardation experienced by the
body member at different locations. Figures show a cycle graph
and a chrono cycle graph.
 Examine- The Questions
Purpose: What is actually done?
Why is it necessary?
Place: Where? Why?
Sequence: When? Why?
Person: Who? Why? Select
Means: How? Why?
Record

Examine

Develop

With a view to: Evaluate

Eliminate
Combine or Rearrange Define

Simplify
Install

Maintain
 Develop

New Designs
Multidisciplinary Teams
Worker Involvement
Select
Quality Circles
Record
Simple Ideas (Spring Loaded Table)
Examine

Develop

Evaluate

Define

Install

Maintain
 Evaluate

Multiple Improvement Ideas

Consider costs, benefits, and drawbacks
Report (ABC, Accurate, Brief, and Clear)
Select
Example
Record

Examine

Develop

Evaluate

Define

Install

Maintain
 Define
The written standard practice
Prepare a written standard practice, also known as an "operative instruction
sheet". This serves several purposes
1. It records the improved method for future reference.
2. It can be used to explain the new method to management, supervisors and
Select
operatives. It also advises all concerned, including the works engineers, of
any new equipment required or of changes needed in the layout of Record
machines or workplaces.
Examine
3. It is an aid to training or retraining operatives.
Develop
4. It forms the basis on which time studies.
Evaluate

Define

Install

Maintain
 Define
The written standard practice outlines in simple terms the methods to be used
by the operative. Three sorts of information will normally be required:
 (1) The tools and equipment to be used and the general operating conditions.
(2) A description of the method. The amount of detail required will depend on
the nature of the job and the probable volume of production. For a job
which will occupy several operatives for several months, the written Select

standard practice may have to be very detailed, going into finger

Record
movements.
(3) A diagram of the workplace layout and, possibly, sketches of special tools, Examine

jigs or fixtures.
Develop

Evaluate

Define

Install

Maintain
 Install
Installation can be divided into five stages, namely:
(1) Gaining acceptance of the change by management.
(2) Gaining acceptance of the change by the departmental supervision.
There is no point in trying to go any further if this approval and Select
acceptance have not been obtained.
Record
(3) Gaining acceptance of the change by the workers and their
representatives. Examine

(4) Preparing to make the changes. Develop

(5) Controlling the changeover.
Evaluate

Define

Install

Maintain
 Install
 Training
May use films to demonstrate the old and the new methods.
Films are particularly valuable when retraining.
Develop the habit of doing the job in the correct way.
Train to follow a numbered sequence illustrated on a chart. Select
Learning curves
Record
In the first stages of learning, rests between periods of practice should be longer
than the periods of practice themselves. Examine

When the operative has begun to grasp the new method and to pick up speed, rest Develop
periods can be very much shorter.
Evaluate
Nursing the new method.
Define

Install

Maintain
 Maintain

workers should not be permitted to slip back into old methods, or Select
introduce elements not allowed for, unless there is very good reason for
doing so. Record

To be maintained, a method must first be very clearly defined and Examine

specified.
Develop
Assign a specialists permanently.
Evaluate
Formal review.
Define

Install

Maintain
Principle of Motion Economy
The principles of motion economy form a set of rules and
suggestions to improve the manual work in manufacturing and
reduce fatigue and unnecessary movements by the worker,
which can lead to the reduction in the work related trauma.

The principles of motion economy are grouped under

three headings:
1. Use of the human body
2. Arrangements of the workplace
3. Design of tools and equipment
 Use of Human Body
1. The two hands should begin and complete their movements at the same time.
2. The two hands should not be idle at the same time except during periods of
rest.
3. Motions of the arms should be symmetrical and in opposite directions and
should be made simultaneously.
4. Hand and body motions should be made at the lowest classification at which it
is possible to do the work satisfactorily.
5. Momentum should be employed to help the worker but should be reduced to a
minimum whenever it has to be overcome by muscular effort.
6. Continuous curved movements are to be preferred to straight-line motions
involving sudden and sharp changes in direction.
7. ‘Ballistic’ (i.e. free-swinging) movements are faster, easier and more accurate
than restricted or controlled movements.
8. Rhythm is essential to the smooth and automatic performance of a repetitive
operation. The work should be arranged to permit easy and natural rhythm
whenever possible.
9.Work should be arranged so that eye movements are confined to a comfortable
area without the need for frequent changes of focus.
 Arrangement of the workplace
1. Definite and fixed stations should be provided for all tools and materials
to permit habit formation.
2. Tools and materials should be pre-positioned to reduce searching. Gravity
fed bins and containers should be used to deliver the materials as close to
the point of use as possible.
3. Tools, materials and controls should be located within the maximum
working area and as near to the worker as possible.
4. Materials and tools should be arranged to permit the best sequence of
motions.
5. ‘Drop deliveries’ or ejectors should be used wherever possible so that the
operator does not have to use his hands to dispose of the finished work.
6. Provision should be made for adequate lighting and a chair of the type
and height to permit good posture should be provided.
7. The height of the workplace and seat should be arranged to allow
alternate standing and sitting.
8. The colour of the workplace should contrast with that of the work and
thus reduce eye fatigue.
 Design of Tools and Equipment
1. The hands should be relieved from ‘holding’ the workpiece
where this can be done by a jig, fixture or foot-operated
device.
2. Two or more tools should be combined wherever possible.
3. Where each finger performs some specific movement, as in
typewriting, the load should be distributed in accordance with
the inherent capacities of the fingers.
4. Handles such as those on cranks and large screwdrivers
should be designed so as to permit as much of the surface of
the hand as possible to come into contact with the handle. This
is especially necessary when considerable force has to be used
on the handle.
5. Levers, crossbars and hand-wheels should be placed so that
the operator can use them with the least change in body
position and the greatest mechanical advantage.
The application of human biological sciences along with
engineering sciences to achieve optimum mutual adjustment of
men and his work, benefit is measured in terms of human
efficiency and well-being.

Definition :
The design of human task, man machine system
and effective accomplishment of job, including
displays for presentation of information to
human sensors, controls for human operation
and complex man – machine system.
Man – Machine System
 Three Aspects of Man – Machine
System
1. Design of information displays
2. Design of controls
3. Environmental factor
1. Design of information displays
2. Design of controls
Toggle Switch
 3. Environmental Factors
Recommendations :
1. Vibration : Less than 20 Hz
2. Thermal Condition : Working Temp: 60-65 °F
3. Ventilation:
 Anthropometry
It deals with the measurement of dimensions and
certain other physical characteristics of body
such as volume, centre of gravity, inertial
properties and masses of body segments.
Workplace Design