Work Study Problem Solving Tools (Part 2

WORK STUDY
AND
MEASUREMENT
Problem Solving
Tools (Part 2)
Andris Freivalds,
Benjamin Niebel -
Niebel’s Methods,
Standards, & Work
Design ( 2013,
McGraw-Hill
Education)
TOPICS TO BE
DISCUSSED
• Exploratory Tools
• Recording and Analysis Tools
• Quantitative Tools, Worker and
Machine Relationship
Andris Freivalds, Benjamin Niebel - Niebel’s Methods, Standards, & Work Design ( 2013, McGraw-Hill Education)
QUANTITATIVE TOOLS,
WORKER AND MACHINE
RELATIONSHIPS
Although the worker and machine

process chart can illustrate the number of
facilities that can be assigned to an
operator, this can often be computed in
much less time through the development
of a mathematical model. A worker and
machine relationship is usually one of
three types: (1) synchronous servicing, (2)
completely random servicing, and (3) a
combination of synchronous and random
servicing.
• QUANTITATIVE TOOLS, WORKER AND MACHINE RELATIONSHIPS -
SYNCHRONOUS SERVICING
Assigning more than one machine to an

operator seldom results in the ideal case where
both the worker and the machine are occupied
during the whole cycle. Such ideal cases are
Where
referred to as synchronous servicing, and the
number of machines to be assigned can be n - number of machines the operator is assigned
computed as: l - total operator loading and unloading (servicing) time per
machine
𝑙+𝑚 m - total machine running time (automatic power feed)

𝑛=
𝑙
For example, assume a total cycle time of 4 min to 𝑙+𝑚

produce a product, as measured from the start of the 𝑛=
unloading of the previously completed product to the 𝑙
end of the machine cycle time. Operator servicing,
which includes both the unloading of the completed 1+3
𝑛=
product and the loading of the raw materials, is 1 min, 1
while the cycle time of the automatic machine cycle is 3
min. Synchronous servicing would result in the 𝑛=4 𝑚𝑎𝑐h𝑖𝑛𝑒𝑠
assignment of
QUANTITATIVE TOOLS,
WORKER AND MACHINE
RELATIONSHIPS -
SYNCHRONOUS
SERVICING
Graphically, this assignment

would appear as shown in the
figure, with the operator moving
to the second machine once the
first machine is serviced. By the
time the fourth machine is
serviced, the operator would
need to return to the first
machine to service it, as that
machine’s automatic cycle
would have just ended.
An additional complication occurs because of less 𝑙+𝑚
than ideal conditions. The operator may need to walk 𝑛 1≤
between machines or clean and adjust the machines. 𝑙+𝑤
This worker time also has to be accounted for based on
the cost of each idle machine and the hourly rate of the Where
operator. n1 - lowest whole number
The number of machines that the operator should w - total worker time (not directly interacting with the
machine, typically walking time to the next machine)
be assigned under realistic conditions can be re-
estimated by the lowest whole number from the l - total operator loading and unloading (servicing) time
per machine
revised equation:
m - total machine running time (automatic power feed)
The cycle time with the operator servicing n 1
machines is l + m, since in this case, the operator is not
busy the whole cycle, yet the facilities are occupied
during the entire cycle.
Using n 1 , we can compute the total expected cost where
(TEC) as follows:
TEC - total expected cost in dollars per unit of
production from one machine
TECn1 K 1 - operator rate, in dollars per unit of time
K 2 - cost of machine, in dollars per unit of time
TECn1
After this cost is computed, a cost should be where
calculated with n1 +1 machines assigned to the
TEC - total expected cost in dollars per unit of
operator. In this case, the cycle time is governed by the production from one machine
working cycle of the operator, since there is some idle K 1 - operator rate, in dollars per unit of time
machine time. The cycle time is now ( n1 + 1)( l + w ). Let
K 2 - cost of machine, in dollars per unit of time
n2 = n1 + 1. Then the total expected cost with n2 facilities
is
TECn2
TECn2
The number of machines assigned depends on

whether n1 or n2 gives the lowest total expected
cost per piece.
SYNCHRONOUS SERVICING (EXAMPLE)
It takes an operator 1 min to service a machine and 0.1 min to walk to the next
machine. Each machine runs automatically for 3 min, the operator earns $10.00/h and
the machines cost $20.00/h to run. How many machines can the operator service?
It takes an operator 1 min to service a machine and 0.1 min to walk to the next machine.
Each machine runs automatically for 3 min, the operator earns $10.00/h and the machines
cost $20.00/h to run. How many machines can the operator service?
The optimum number of machines that the operator can service is
𝑙+𝑚 1+3
𝑛= 𝑛= 3.6 machines
𝑙+𝑤 1+0.1
Option 1: 3 machines
TECn1
TEC3 TEC3
Option 2: 4 machines TECn2
TEC4 TEC4
Based on lowest cost, the setup with three machines is best. However, if there is market
demand at a good sales price, profits can be maximized using a four-machine setup.
Rate
TECn1 TECn2
R R
R R
TEC3 = TEC4 =
TEC3 TEC4
Note the effect of reducing loading/unloading time from 1. min to 0.9 min, a relatively small
amount. The optimum number of machines that the operator can service is now
𝑙+𝑚 0.9+ 3
𝑙+𝑤 0.9+ 0.1
TECn1 TEC3 TEC3
R R
𝑙+𝑚 0.9+ 3
𝑙+𝑤 0.9+ 0.1
TECn2 TEC4 TEC4
R R
l=1 l = 0.9
TEC3 TEC3
R R
TEC4 TEC4
R R
RANDOM SERVICING
Completely random servicing situations are those cases in
𝑛!
which it is not known when a facility will have to be serviced or 𝑃 ( 𝑚 𝑜𝑓 𝑛 )= 𝑥 𝑝𝑚𝑞𝑛− 𝑚
how long servicing will take. Mean values are usually known or 𝑚 ! ( 𝑛 −𝑚 ) !
can be determined; with these averages, the laws of probability
can provide a useful tool in determining the number of Where
machines to assign to a single operator.
n - number of machines the operator is
assigned
The successive terms of the binomial expansion give a useful m - number of machines down
approximation of the probability of 0, 1, 2, 3, . . . , n machines p - probability of downtime
down (where n is relatively small), assuming that each machine
is down at random times during the day (due to servicing and q - probability of runtime
machine interference) and that the probability of downtime is
p and the probability of runtime is q = 1 – p . Each term of the
binomial expansion can be expressed as a probability of m (out
of n ) machines down:
RANDOM SERVICING
Source: https://www.youtube.com/watch?v=no4WcFqcGso
RANDOM SERVICING
RANDOM SERVICING (EXAMPLE)
𝑛!
𝑃 ( 𝑚 𝑜𝑓 𝑛 )= 𝑥 𝑝𝑚𝑞𝑛− 𝑚
𝑚 ! ( 𝑛 −𝑚 ) !
College of Engineering
Bachelor of Science in Industrial Engineering
How about 1 operator? Exercise!

ANY QUESTIONS?
45
Occupational Safety and Health Management System by International Labor Organization (ILO)
References:
•Andris Freivalds, Benjamin Niebel - Niebel’s
Methods, Standards, & Work Design ( 2013, McGraw-
Hill Education)
•Operations Management by Heizer and Render
•Photos by google
46
Occupational Safety and Health Management System by International Labor Organization (ILO)

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WORK STUDY

Although the worker and machine

Assigning more than one machine to an

𝑙+𝑚 m - total machine running time (automatic power feed)

For example, assume a total cycle time of 4 min to 𝑙+𝑚

Graphically, this assignment

The number of machines assigned depends on

The optimum number of machines that the operator can service is

Option 2: 4 machines TECn2

TECn1 TEC3 TEC3

TECn2 TEC4 TEC4

How about 1 operator? Exercise!

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