Work Study is defined as a collection of techniques used to

examine work - what is done and how it is done - so that there is systematic analysis of all the elements, factors, resources and relationships affecting the efficiency and effectiveness of the work being studied.
Work Study is defined as the systematic examination of the

methods of carrying on activities so as to improve the effective use of resources and to set up standards of performance for the activities being carried out.

WORK STUDY
Technique used in the examination of human work in all

contexts, and which lead systematically to the investigation of all the factors which affect the efficiency and economy of the situation being reviewed, in order to effect improvement. Two branches method study and work measurement. Widely known as time and motion study. Rapid developments after World War II. Huge capital investment in process R&D may increase productivity. However, it is expensive and time consuming. Work study focuses on human workers and can increase productivity at a lower cost.

WORK STUDY
Since line managers are typically busy with the day-to-day

activities, they can only look at work study during their free time. They should not be entrusted with the work study responsibilities. Workers also ruled out because they usually lack the knowledge of the big picture. Therefore, responsibility should be given to someone who can work full-time on work study, without direct management duties. Someone in the staff and not a line position.

WORK STUDY: A TOOL FOR MANAGEMENT(uses)

1. Means of raising productivity (and efficiency) of the factory
2. 3.

4. 5.
6. 7.

by reorganization of work. Typically involves low or no capital expenditure. Systematic process Covers all aspects of raising productivity. Very accurate in setting standards of performance. Savings from work study start at once and continues as long as the improved operations are performed. Applied everywhere: not only in manufacturing shops, offices, shops, stores, laboratories; and service industries like restaurants, etc. One of the most penetrating tools of investigation available to management.

WORK STUDY: BEYOND SYSTEMATIC

Should be applied continuously, and throughout the

organization. Basis of successful work study: complete intolerance of waste in any form whether of material, time, effort or human ability.

TECHNIQUES OF WORK STUDY

Method study Systematic recording and critical examination

of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs. Work measurement 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. Method study is associated with the reduction of the work content of a job or operation, while work measurement is mostly concerned with the investigation and reduction of any ineffective time associated with it.

BASIC PROCEDURE OF WORK STUDY

1. 2. 3.

4.

5.

6. 7. 8.

Select the job or process to be studied. Record from the direct observations everything that happens. Examine the recorded facts critically and challenge everything that is done. Develop most economic method taking in to considerations all circumstances. Measure the quantity of work involved in the method selected and calculate a standard time for doing it. Define the new method and time to standardize. Institutionalize the new method and time as practice. Maintain the new standards by control procedures.

METHOD STUDY
Method study is the systematic recording and critical

examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs.
It uses different sets of techniques to do so. is an analysis of

ways of doing work. a common-sense heuristic or general problem-solving strategy

OBJECTIVES
Improvement of processes and procedures. Improvements of factory, shop and workplace layout and of

design of plant and equipment. Economy of human efforts and the reduction of unnecessary fatigue. Improvement in the use of materials, machines and manpower. The development of a better physical working environment.

 SEVEN STEPS of Carrying Out Method Study: The Process

1. Define existing method.

2. Record existing method. 3. Examine existing method.

4. Develop new method.

5. Define new method. 6. Install new method. 7. Maintain new method.

DIFFERENT RECORDING TECHNIQUES

1. Outline process charts 2. Flow process chart: man type, material type, equipment type 3. Two handed process chart 4. Multiple activity chart: using time scale

5. Simo chart: using time scale

6. Flow diagrams 7. String diagrams

8. Cyclograph
9. Chronocyclegraph 10. Travel Chart

SELECTING THE WORK TO BE STUDIED

Economic considerations Bottlenecks Movements of material over long distances Operations involving repetitive work Technical considerations Relatively straight forward Based on the technical knowledge of the process Human considerations Most difficult to foretell because of mental and emotional nature. Select an unpopular job for method study.

(discussion ) IMPORTANT CONSIDERATIONS

1. 2. 3. 4.

5.
6. 7. 8.

Product and operation Person who proposed investigation Reason for proposal Particulars of the job Equipment Layout Product Savings and/or increase in productivity expected.

METHOD STUDY CHARTS AND DIAGRAMS

Charts indicating process Charts using a time scale

sequence - Outline process chart - Flow process chart Man, Material and Equipment type - Two-handed process chart

- Multiple activity chart - Simo chart - PMTS chart

Diagrams indicating movement - Flow diagram - Chronocyclegraph - Sting diagram - Travel chart - Cyclograph

METHOD STUDY CHARTS AND DIAGRAMS

Outline process chart: Is a process chart giving an overall-

picture by recording in sequence only the main operations and inspections. Flow process chart: A chart setting out the sequence of flow of a product or a procedure b recording all events under review using the appropriate chart symbols. Man-type Records what the worker does Material-type Records what happens to materials. Equipment-type Records how the equipment is used.

WHY CHARTS?

1. 2.

3.
4. 5.

It gives a complete picture of what is being done and helps to understand the facts and its relationship to one another. Details on the chart must be obtained from direct observation. Should not be from memory. Neatness and accuracy important. Increased value if following is included: Product, equipment details (code#, drawing#) Job or process being carried out Location and time (date) of the study Observers name Chart reference number

EXAMINE CRITICALLY
Means by which each activity is subjected to a systematic and

progressive series of questions. Grouping of activities: Five sets of activities can be grouped in two categories Those in which something actually happens to the work-piece (it is moved, worked upon or examined) Those in which it is not being touched (in storage or in delay) Objective is to maximize proportion of do activities. All other activities, however necessary, are considered nonproductive.

PRIMARY QUESTIONS
The PURPOSE

for which The PLACE at which The SEQUENCE in which The PERSON by whom The MEANS by which .the activities are undertaken. With a view to ELIMINATING, COMBINING, REARRANGING, or SIMPLIFYING those activities.

PRIMARY QUESTIONS
PURPOSE PLACE SEQUENCE PERSON What? Why? Where? When? Who? COMBINE wherever possible or REARRANGE the sequence for better result ELIMINATE unnecessary part of the job

MEANS

How?

SIMPLIFY the operation

THE SECONDARY QUESTIONS

PURPOSE PLACE SEQUENCE PERSON What else might be done? What should be done? Where else might be done? Where should be done? When else might be done? When should be done? Who else might be done? Who should be done? How else might be done? How should be done?

MEANS

FACILITY LAYOUT: METHOD STUDY CONSIDERATIONS

Important considerations: Easiest flow of material, at the

lowest cost and with minimum handling. Essentially a work study problem. More recently, because of cost minimization aspects, Operations personnel solves the layout problem. Work study methods: Flow diagram and process flow chart. Flow diagram 3D diagram and/or model, 2D cardboard models and 3D wood/plastic models. Ensure that diagrams/models are to the scale. Err on the safe side. CAD models more common now.

FACILITY LAYOUT: METHOD STUDY CONSIDERATIONS

Start with the flow diagram/model.
Map all the material movements on the flow diagram/model. Measure distances of travel (computer output, thread method,

drawing lines on the diagram etc.) Analyze the current practice using a flow chart. Go through the usual rounds of primary and secondary questions. Develop the improved method.

MATERIAL HANDLING
Typically material handing may take up to 85% of the total

process time. Only important method study principle: Motion Economy! Material handling adds to the cost of manufacture but adds nothing to the value of the product. Therefore, ideally there should be no material handling. Typical material handling problem solved in the same way as all method study problem start with asking questions.

Most important question: WHY is this handling done?

MATERIAL HANDLING: PROCESS

Traditional way of solving any method study problems
Use of outline and process flow charts and flow diagrams to

ensure a correct workplace layout. AIM: Minimization of movement in any plane horizontal or vertical. Specially critical when one is buying material handling equipment for the workplace. Change in workplace layout affects not only the quantity but also the type of material handling equipment necessary.

MATERIAL HANDLING: IMPORTANT ASPECTS

1. Always try to keep material at the height at which they are to
2. 3.

4. 5. 6. 7. 8.

be worked upon. Never keep material on floor. Always keep distances over which material is handled as short as possible. Let gravity work for you. Always handle in bulk over distances. Always have sufficient boxes, platforms or container available at the workplace. Keep gangways clear. Dont reduce the supplementary human labor if it means increase in the load for direct operators.

EFFECTS OF SHOP LAYOUT ON WORKER MOVEMENT

There are many activities in which workers move at irregular intervals between a number of points in the working area, with or without material. This happens when, Bulk material is fed to or removed from a continuous process. An operator is looking after two or more machines. Laborers are delivering material to or removing work from a series of machines. In stores and shops when variety of materials are being removed from or put away into racks or bins. In restaurants and canteens kitchens during preparation of meal.

WORK MEASUREMENT

WORK MEASUREMENT
Work measurement is the application of techniques designed to

establish the time for a qualified worker to carry out a task at a defined level of performance.
It measures the time taken in performance of an operation or a

series of operations and it can separate out ineffective time from effective time. Thus ineffective time can be studied and by way of method study described

OBJECTIVES OF WORK MEASUREMENT

1. Finding ineffective time in an activity or a process (series of 2. 3. 4.

5.
6. 7.

activities). Setting standard (norms) for output level. Evaluating workers performance. Assessing and planning manpower needs. Determining available capacity. Comparing various work methods. Facilitating operations scheduling.

8. Establishing wage incentive schemes.

SOME TECHNIQUES OF WORK MEASUREMENT

Stop-watch time study.

Work sampling. Predetermined time standards (PTS). Standard Data.