PERANCANGAN SISTEM KERJA DAN ERGONOMI (IEI2H3)

Stopwatch Time Study,

Performance Rating, and
allowance

Prepared by:
Team teaching (DCO, YGN, IKP, ATU, MRY, YFN)

Prodi S1 Teknik Industri

Fakultas Rekayasa Industri
Universitas Telkom
 Work Measurement

A techniques used to establish the workload and work

performance obtained at a defined work system.
physical load
• load experienced
Workload : by worker psychological load

Work • output and speed at a work

system (measure quantity for
performance: certain quality) Time Study

“Standardized the work system”

 Time Study (1)
Objectives :
by a given method, Develops a standard time for
performing a task

by a given working ec.europa.eu

condition, Improves the work method

by a trained and Measures work content, allows

for fatigue, personal and
qualified worker, unavoidable delays
www.blog.internshala.com

working in a normal Increases the efficiency of the

pace. equipment and personnel www.4cleanair.org

www.pmcorp.com
 Time Study (2)
Direct time study: the
work (time) measurement
conducted when the job
executed (in the same
place)
Time
study
Indirect time study: the
observer and the workers
don’t need to be in the
same place when the
measurement conducted.
 Comparison of Direct and Indirect
Measurement
Method Positive Negative
Practical, because doesn’t Need more time, because the
need to breakdown the measurement can be done when the
activity into elements worker do the activity
DIRECT
Need a larger number of observation to
get a assured and valid data

Completion time can be

estimated before the Need accuracy when
activity, when the elements breakdown the activity into
are known. elements
INDIRECT Shorter time Motion time data must be adapted to
work system condition
Lower cost

http://ww.itimes.com/
 Time Study (2)
Indirect Direct
measuremen Measureme
t nt
Standard
time data Stopwatch
www.cathedralgrammar.school.nz

www.timbryce.com

Motion Work
time data sampling
www.publicitefes.com
www.drsalanger.com
 Pengukuran Waktu Metoda Jam Henti
(Stopwatch Time Study)

A direct work measurement that applicable for

repetitive job
 Standard time
Time needed for conducting a cycle of work

As a standard (time) for the workers to finish their job

The amount of time it should take a qualified worker to :

• complete a specific task,
• working at a sustainable rate

using given
• methods,
• tools and equipment,
• raw materials,
• workplace arrangement.
www.lovebeingretired.com
 Needs for Standard Time
Developing schedules

Determining wage payment plans

Estimating production costs

Providing a base for estimating

productivity goals

Appraising employee performance

Evaluating alternative process,

equipment
www.govcentral.monster.com
 Time Study Procedure
1. Pilot study
1. What for? 2. Improves the workers
2. How big is the level action and condition 1. Normal skill
of accuracy and level 3. Standardized the good 2. Good team work
3. Work properly (wajar) Learning curve
of confidence? work system

1 2 3 4
• Define objective • Sampling x • Worker selection • Worker training
of the study observations

5 6 7 8
• Breakdown task x • Prepare the • Do the x • Calculating:
x cycle
into element measurement observations – time, normal time,
tools time study standard time
Stopwatch, observation
sheet, pen/pencil,
observation board

Before the After

observation observation observation
 Step 1. Define objective of the study
This involves statement of the use of the result,
the desired accuracy, and the required level of
confidence in the estimated standard time.
 Step 2. Sampling observations
Verify that the standard method and conditions exist for
the operation and the operation is properly trained.

Record information product or part being

processed
about : www.fixoldtractors.com

process, method, plant

or machine www.vem.eu

operator
www.kraussmaffei.com

duration
www.musbikhin.com

working condition
www.wamda.com

http://www.mylearning.org/
 Step 3. Worker selection
• Select an Average Worker (What is average?)

Number
of
Worker

Low Average High

Worker Ability
http://ww.itimes.com/
Step 3. Worker selection (cont’d)

Experienced operator

Normal pace

Support the objective of the

measurement
http://ww.itimes.com/
 Step 4. Worker training
Sometimes, the workers need to be trained before the
experiment conducted due to the unfamiliarity with the
job that may exist, especially for a job with different
condition and different method

Learning curve
Worker Skill

Time
http://ww.itimes.com/
Step 5. Breakdown task into elements

An • is a distinct part of a specified job

elemen selected for convenience of observation,
measurement and analysis.
t
• is the sequence of elements which are required
to perform a job or produce a unit of
A work production. The sequence may sometimes
include occasional elements.

cycle • starts at the beginning of the first element of

the operation or activity and continues to the
same point in a repetition of the operation or
activity.
 Step 5. Breakdown task into elements
(cont’d)
Element analysis :
Every element must have an easily identifiable starting
and ending point (breakpoints)

One movement or combinations of movements (eg.

Gilbreth movement)

Elements should be as short as can be easily timed by a

trained observer.

www.jansait.com
 Step 6. Prepare measurement tools

a. Stopwatch

b. Observation sheet

c. Pen or pencil

d. Observation board www.insta20.com

 Time Measurement Technique Using
Stopwatch
Continuous timing
• Let the stopwatch run continuously
from the beginning to the end of
work cycle

Repetitive timing (snap back

method)
• The stopwatch run only for every
work element

Accumulative timing
• Need two stopwatches
 Step 7. Do the observations
1. Preliminary study

• Objective: to get the statistical estimation

for the number of observations, based on
a certain accuracy level and confidence
level. www.dawtek.com.au

• Accuracy level show “maximum

deviation” between measurement result
and real completion time  described in
%
• Confidence level show the confidence of www.alumnilocators.com

analyst that the measurement result fulfill

the accuracy level described in %
www.dreamstime.com
Step 7. Do the observations (cont’d)
excluded

included

excluded

www.pqsystems.com

N’>N : data is not adequate

need more observation

N’=<N : data is adequate 

doesn’t need more observation
 Example
Result from sampling measurement :
Observation 1 2 3 4 5 6 7 8
Time 14 10 12 15 17 18 15 16

Observation 9 10 11 12 13 14 15 16

Time 11 9 14 16 10 18 14 15

www.colourbox.com
A. Dividing data into several subgroup

Subgroup Completion time ) Average values

1 14 10 12 15 12,75
2 17 18 15 16 16,50
3 11 9 14 16 12,50
4 10 18 14 15 14,25

Total 56,00

B. Calculate the (overall) average values () based on

average values for each subgroup ()

´=
𝑥
∑ 𝑥𝑖 average values from subgroup

𝑘
number of subgroup
 Average Grand
Subgroup Completion time ) values( 𝑥𝑖 ) mean ( )
1 14 10 12 15 12,75 …….
2 17 18 15 16 16,50 Previously
3 11 9 14 16 12,50 calculated
4 10 18 14 15 14,25 (see slide 22)

Total
C. Calculate standard deviation 56,00
completion time based Number of
on observations observation :
16

number of observations from preliminary study

 Grand Deviation
Subgroup Completion time (xj) Average
values mean standard
( ) ( )
1 14 10 12 15 12,75 ……. …….. Previously
2 17 18 15 16 16,50 calculated
3 11 9 14 16 12,50 (see slide
4 10 18 14 15 14,25
23)

Total 56,00
D. Calculate standard deviation of sub-groups’ mean distribution :

𝜎
𝜎 𝑥=
√𝑛 number of observation in a subgroup
 Standard
Deviation ( ) Standard
deviation of
Subgroup Grand
Completion time (xj) Average sub-groups’
values mean Previously mean
( ) calculated distribution :
(see slide ( )
24)
1 14 10 12 15 12,75 ……. …….. …..
2 17 18 15 16 16,50
3 11 9 14 16 12,50
4 10 18 14 15 14,25

E. Calculate Upper Control Limit (UCL) and Lower Control Limit (LCL)
𝑈𝐶𝐿=
Total
´
𝑥 + 𝑍 𝑡 𝜎 An index, derived from the confidence level:
56,00 0%-68%=1, 69%-95%=2, 96%-99%=3
𝑥
𝐿𝐶𝐿= 𝑥´ − 𝑍𝑡 𝜎 𝑥

Group above or below the control limit must be excluded

 Observation 1 2 3 4 5 6 7 8
Time 14 10 12 15 17 18 15 16 N : 16
Observation 9 10 11 12 13 14 15 16 xi

Time 11 9 14 16 An10index,
18derived
14 from
15 the confidence level:
0%-68%=1, 69%-95%=2, 96%-99%=3

( )
F. Calculate number of observation needed 𝑧𝑡
2

Accuracy ′
𝑁=
𝛼 √
𝑁 . ∑ 𝑥 𝑖 − (∑ 𝑥 𝑖 )
2 2

level
∑ 𝑥𝑖
Formula for accuracy level 5 % and confidence level 95 %.

( √
)
2 number of
40 𝑁 . ∑ 𝒙 − ( ∑ 𝑥 𝑖 )
𝟐 2
number of data based
′ 𝒊 observation
𝑁= observations on
∑ 𝑥𝑖 needed
based on
preliminary preliminary
study study
If N’ > N : need more observation (data is not adequate)
If N’ ≤ N : doesn’t need more observation (data is adequate)
Step 8. Calculating
• Calculate cycle time
1

• Define performance rating

2

• Calculate normal time

3

• Determine allowances
4

• Calculate standard time

5
www.drdarman.ir
 Cycle Time (CT) / Waktu Siklus (Ws)
Observation 1 2 3 4 5 6 7 8
Time 14 10 12 15 17 18 15 16

Observation 9 10 11 12 13 14 15 16

Time 11 9 14 16 10 18 14 15
Cycle time means observed time required for a worker to perform the task

The time to finish one “unit” of production

Cycle time can be calculated using formula

𝐶𝑇 =
∑ 𝑥𝑖
value of data
𝑁
Cycle time
Number of
Observation
 Normal Time (NT) / Waktu Normal (Wn)

The time required for an average, trained operator

to perform a task under usual working conditions
and working at a normal pace. (It does not include
allowances for personal needs and delays)

Normal time can be calculated using formula :

PRF=1 : normal work

𝑁𝑇 =𝐶𝑇 × 𝑃𝑅𝐹 PRF<1 : work too slow
PRF>1 : work too fast
PRF = Performance Rating Factor
 Performance Rating

Assessing the operator’s effective speed of working relative to the

observer’s concept of the rate corresponding to standard rating.

Objective
• Normalize the cycle time due to the abnormal operator’s working speed

Normal pace
• Experienced worker
• Without significant effort
• Know how to conduct the job well
• Eager to conduct the job
Methods to Define Performance Rating

Percentage
Shumard

Subjective judgment Objective

Methods: Westinghouse
Performance Rating using Percentage Method

A certain “percentage” based on subjective judgement of

the observer
According to the
observation result, it is
decided to have the
For example : performance rating (PRF)
110%
• NT = 14,6 X 110% = 16,06 min

This method is the most easy and simple, but the result is
rough -- not accurate (rely on the subjective judgement)
Performance Rating using Shumard Method
PERFORMANCE RATING The rating is defined
CLASS FACTOR according to “work
Super fast 100 performance” class. Every
Fast + 95 class has its own rating.
Fast 90
Fast - 85
Excellent 80 𝑷𝑹𝑭 𝑶𝒃𝒔𝒆𝒓𝒗𝒆𝒅𝑾𝒐𝒓𝒌𝒆𝒓
𝑷𝑹𝑭 =
Good + 75 𝑷𝑹𝑭 𝑵𝒐𝒓𝒎𝒂𝒍 𝑾𝒐𝒓𝒌𝒆𝒓
Good 70 Exp: An operator’s
Good - 65
Normal 60 performance is rated as
Fair + 55 “excellent”. CT = 124.6 s.
Fair 50 Calculate the PRF and the NT!
Fair - 45
PRF = 80/60 = 1.33
Poor 40
NT = CT x PRF = 124.6 x 1.33 = 166.133 s
Performance Rating Using Westinghouse Method
Operator’s
Ability to
eagerness
follow the
when
work
conduct the
procedure
job

Condition
The
of the
similar
physical
result of
environm-
the
ent
working
(lighting,
time
temperat-
measure
ure,
ment
noise)
𝑷𝑹𝑭 =𝟏+𝑺𝒌𝒊𝒍𝒍+𝑬𝒇𝒇𝒐𝒓𝒕+𝑪𝒐𝒏𝒅𝒊𝒕𝒊𝒐𝒏+𝑪𝒐𝒏𝒔𝒊𝒔𝒕𝒆𝒏𝒄𝒚
Performance Rating Using Westinghouse Method
(2)

Fair (E1) = -0.05

Good (C2) = 0.02
CT = 124.6 Excellent (B) = +0.04
Poor (F) = -0.04
Skill Fair (E1) Total = -0.03

PRF = (1-0.03) = 0.97

Effort  Good (C2) NT = 124.6 x 0.97 = 120.862

Condition  Excellent (B)

Consistency  Poor (F)

 Performance Rating using Objective Method
Considering Work Work
two factors speed difficulties

PRF
PRF
Work PRF Work Difficulties
Speed

Based on 4. 5.
1. Used 6.
PRF 2. Foot 3. Use of Coordinatio
body Tools and
Shumard pedals hand n of eye and Weight
parts equipment
Method hand

𝑷𝑹𝑭 =𝑷𝑹𝑭 𝑾𝒐𝒓𝒌 𝑺𝒑𝒆𝒆𝒅 𝒙 𝑷𝑹𝑭 𝑾𝒐𝒓𝒌 𝑫𝒊𝒇𝒇𝒊𝒄𝒖𝒍𝒕𝒊𝒆𝒔

𝑷𝑹𝑭𝑾𝒐𝒓𝒌 𝑫𝒊𝒇 𝒊𝒄𝒖𝒍𝒕𝒊𝒆𝒔=𝟏+𝑼𝒔𝒆𝒅𝑩𝒐𝒅𝒚𝒑𝒂𝒓𝒕+𝑭𝒐𝒐𝒕𝑷𝒆𝒅𝒂𝒍𝒔+𝑼𝒔𝒆𝒐𝒇𝒉𝒂𝒏𝒅+𝑪𝒐𝒐𝒓𝒅𝒊𝒏𝒂𝒕𝒊𝒐𝒏𝒐𝒇𝒆𝒚𝒆𝒂𝒏𝒅𝒉𝒂𝒏𝒅+𝑻𝒐𝒐𝒍𝒔 𝒂𝒏𝒅𝑬𝒒𝒖𝒊𝒑𝒎𝒆𝒏𝒕+𝑾𝒆𝒊𝒈𝒉𝒕

 Work Difficulties Table as the Objective Factor
1. USED BODY PART
Fingers (Jari) A 0
Wrist and fingers (Pergelangan Tangan Dan Jari) B 1
Lower arm, wrist, and fingers (Lengan Bawah, Pergelangan Tangan Dan Jari) C 2
Upper arm, lower arm, etc (Lengan Atas, Lengan Bawah dst) D 5
Body (Badan) E 8
Lifting (Mengangkat Beban dari Lantai dengan Kaki) E2 10

2. FOOT PEDALS
Without pedals (Tanpa Pedal, atau Satu Pedal dengan Sumbu di bawah Kaki) F 0
One or two pedals (Satu atau Dua Pedal dengan Sumbu tidak di bawah Kaki) G 5

3. USED OF HAND
Both hands work independently (Kedua tangan saling bantu atau bergantian) 0
Both hands work simultaneously (Kedua tangan mengerjakan gerakan yang sama) 18
H

H2

In %
Work Difficulties Table as the Objective Factor
(2)
4. COORDINATION OF EYE AND HAND
Very few (Sangat sedikit). I 0
Close enough (Cukup dekat). J 2
Constant and close (Konstan dan dekat) K 4
Very close (Sangat dekat) L 7
Smaller than 0.04 cm (Lebih kecil dari 0,04 cm) M 10

5. TOOLS AND EQUIPMENT

Easily handled (Dapat ditangani dengan mudah) N 0
Need small control (Dengan sedikit control) O 1
Need control and emphasize (Perlu control dan penekanan) P 2
Need careful handling (Perlu penanganan hati – hati) Q 3
Fragile (Mudah pecah dan patah) R 5

In %
Work Difficulties Table as the Objective Factor
(3)
WEIGHT (kg) Hand Foot
0,45 B -1 2 1
0,90 B-2 5 1
1,35 B-3 6 1
1,80 B-4 10 2
2,25 B-5 13 3
2,70 B-6 15 3
3,15 B-7 17 4
3,60 B-8 19 5
4,05 B-9 20 6
4,50 B-10 22 7
4,95 B-11 24 8
5,40 B-12 25 9
5,85 B-13 27 10
6,30 B-14 28 10

In %

40
Performance Rating using Objective Method
(Example)
CT = 124.6 ; PRF Work speed = 0.9
PRF Work Difficulties:

Sum = 23 (%)

𝑃𝑅𝐹 =0.9 × 1.23 =1.107

𝑁𝑇 =124.6 𝑥 1.107 =137.9322
41
Performance Rating using Bedaux and Synthesis
Bedaux
Similar to Shumard method
Using “B (Bedaux)” prior the PRF value
Exp
• 60B
• 80B
PRF = Average (17/17 + 12/10 + 29/32) = 1.04
NT = 124.6 x 1.04 = 129.58
Synthesis
The average of the comparison
between the standard time from
motion element table with the actual
time from the observation
Actual time (Observed time)
• Motion element 1 : 17 s
• Motion element 2 : 10 s
• Motion element 3 : 32 s
Standard time (obtained from table)
• Motion element 1 : 17 s
• Motion element 2 : 12 s CT = 124.6 s
• Motion element 3 : 29 s
 Standard Time (ST) / Waktu Baku (Wb)
Standard time is the total time in which a job should be completed at standard performance.

The normal time needed for a normal worker to conduct the job in the best work sistem

Calculating standard time

𝑆𝑇 =𝑁𝑇 ×(1+ 𝐴𝐹 )

Normal Time Rest Pers. Need Delay

Standard Time
 Allowances
The allowance factor (AF) is the amount of time allowed for personal
needs, fatigue, and unavoidable delays.
Basic fatigue
• Decreasing productivity

Personal Need
• Drink
• Toilet
• Chit chat to avoid boredom

Unavoidable delay
• Asking for instruction
• Machine set up
• Mend the bottleneck
• Sharpen the cutting tools
• Taking special tool from the warehouse www.brigadebookkeeping.com

See Book Reference, pg. 170-171

 Allowances (2)
Components of Allowances See the allowance table
1. Allowance for work fatigue in the book (page 170-
• Force 171)
• Work posture
• Work motion
• Eye fatigue
• Temperature
• Air circulation
• Working environment

2. Allowance for personal needs

• Men
• Women

3. Unavoidable delay
www.brigadebookkeeping.com
 Allowance (3)
Examples
• Allowance for work fatigue
– Force: very low =6%
NT = 54 s
– Work posture: sit =1%
– Work motion: difficult =5%
– Eye fatigue: continuous with fix focus, bad lighting =16%
– Temperature: low with normal fatigue =10%
– Air circulation: good =0%
– Working environment: very noisy =5%
• Man’s personal needs =2%
• Unavoidable delay =5%
• AF=50%
• ST = 54 x (1+ 50%) = 81 s
 Example:
• Allowance for work fatigue
• Given data (s): – Force: Ignorable =5%
– Work posture: sit =1%
2.21 1.51 2.1 – Work motion: difficult =5%
2.1 2.29 2.07 – Eye fatigue: continuous with fix focus, bad lighting =16%
2.02 2.03 2.15 – Temperature: low with normal fatigue =10%
1.56 1.57 2.15 – Air circulation: bad =10%
– Working environment: very noisy =5%
• Calculate:
• Woman’s personal needs =3%
• Cycle time • Unavoidable delay =1%
• Normal
time
• Standard
time • Shumard: Excellent

accuracy level 5%, confidence level 95%

Assume the data is adequate

47