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Method Study
Method Study
to improve
methods of production Work which can be studied
With economic advantage
Define Scope of Study At Work Place
At Work
Record By means of
Place
By means of
Outline Process ; Charts
Two handed ; Simo ; Multiple
Charts Flow Process – Man type , Material
Activity
type ;
Multiple Activity ; Travel Cycle Graphs ; Chronocycle Graphs Other Means
Other Means Flow Diagrams ; String Diagrams ; ;
Models Film Analysis ; Memotion
Examine the facts
Photography
critically
Challeng
e
PURPOSE – PLACE – SEQUENCE – PERSON - MEANS
Seek
Alternatives
Find
Pointers
Eliminat Combine or Simplify
e Change
Develo
A record pof an improved
method
Re -
Planning and Control that record
Examineto Mechanical Aids ;
Materials Handling establish Manual Controls and Visual
The Best Method under Prevailing Circumstances instruments
General Environment and
Equipment design ; Jigs and
Working Conditions Defin fixtures
Plant Layout e Local Working Conditions
Install
The Improved
method
Plan - Arrange -
Implement
Maintai
n
Verify at regular intervals that
The important method as defined is in fact in use
To achieve
improved factory and work space
layout
Improved design of equipment Higher
Better working conditions Productivity
Reduction of fatigue
Resulting in improved use of material
Plant and equipment
Selection Of Job
Factors o be considered in selecting a job for
method study:
Economic Consideration.
Technical Consideration.
Human Reactions.
Economic Consideration.
The cost of the study should be estimated
and examined: short-term & Long-term.
The loss of time due to the investigation.
For any job, if accumulated estimated
benefits from the recommended method
outweighs the estimated total cost then we
should take-up the job under study –
Discounted Cash Flow Technique (DCF) or
Selection Of Job…
Operation
Inspection
Transport
Indicates the movement of workers, materials or equipment from place
to place
Process Chart Symbols…
Temporary Storage or Delay
Permanent Storage
Combined Activities
Man type
– Flow chart which records what the worker does
Material type
– Flow chart which records how material is handled or
treated
Equipment type
– Flow chart which records how the equipment is
used
FLOW PROCESS CHART FOR
ENGINE
Stripping – Cleaning - Greasing
Critical Examination
The questioning technique is the
critical means by which the
critical examination is conducted
– each activity being subjected in
turn to a systematic and
progressive series of questions
OPERATIONS
Make Ready
Do
Put Away
Make ready and put away operations can
be represented by transport and
inspection symbols
DO operations can be shown by “O”
CRITICAL EXAMINATION
- Primary questions
The Purpose for which…
The Place at which…
The sequence in which…
The person by which…
The means by which…
Eliminating
Combining
Rearranging
Simplifying
…those Activities
PRIMARY QUESTIONS
PURPOSE ELIMINATE
PLACE COMBINE
SEQUENCE REARRANGE
PERSON REARRANGE
MEANS SIMPLIFY
THE SECONDARY QUESTIONS
Definition
The secondary questions cover the second
stage of the questioning technique, during
which the answers to the primary
questions are subjected to further query to
determine whether possible alternatives to
place, sequence, persons and/or means
are practicable or preferable as the means
of improvement up on the existing method
SECONDARY QUESTIONS…
During the second stage
of questioning, we should
address
– What else might be done? These questions are the
– What should be done? basis for a systematic
Purpose method study.
Place
Sequence
Person
Means
EXAMPLE: ENGINE
Stripping – Cleaning - Degreasing
DEVELOP
IMPROVED METHOD
After critically examining and
sequential questioning we
develop the improved method
and record the improved method
in a flow process chart as shown
TOOLS USED FOR PREPARING
PLANT LAYOUTS
String diagram
Flow Process chart
Travel Chart
Flow diagram
Multiple activity chart
Template Models
3.ii.D.1 String diagram 1/6
Step-1
– Preparing a study chart
Step-2
– Drawing a scale plan of the working area
Step-3
– Combining steps 1,2 to construct the final diagram
Step-1: Preparing a study chart
Always a square
A column at (m,n) is checked only when there
is a direct movement from station at m to
station at n directly.
The number of times a column at (m,n) is
checked over a period of time gives the
frequency of movement of a worker or material.
The matrix is always a symmetrical matrix.
Travel chart
3.ii.D.4 FLOW DIAGRAM
While the flow process chart describes the flow of a
product or process, it is generally supplemented with a
flow diagram.
While the flow process chart records travel distances
and time taken for various operations, the flow diagram
is a plan , drawn to scale of the work area, correctly
indicating the position of machines and working
positions.
The symbols are also indicated in the flow diagram.
The example shown indicates the flow diagram of receiving,
inspection, marking and storing materials.
After recording examining and developing a new method, the
improved flow diagram shows the transport operations reduced
from a 11 to 6. delays from 7 to 2. and the distance travelled
reduced from 56.2 to 32.2
Original Flow Diagram Inspection and Marking
Improved FD of Inspection and
Marking
3.ii.E.
MULTIPLE ACTIVITY CHART
Multiple activity chart is a useful recording tool
for situations where the work involves the
interaction of different persons. Such as the
operator working on different machines.
In Mac a time scale is used.
Mac can be used effectively even if there is no
movement of workers involved in the work under
consideration.
Focus on Mac in situations where the operator
are moving and to identify the idle time of the
worker or the machine
Multiple activity chart
A MULTIPLE ACTIVIITY chart is a chart in which
the activities of more than one subject (worker,
machine or item of equipment) are each
recorded on a common time scale to show their
inter relationship.
By using separate vertical columns or bars, to
represent the activities of different operatives or
machines against a common time scale, the
chart shows very clearly periods of idleness on
the part of any of the subjects during the
process.
Inspection of catalyst in a converter
The following slides show the present method of
inspecting catalyst in a convertor where teams of
electrician and mate, fitter and mate, rigger and
process man are working together.
In the original method it took 6 mins for the
inspn.
After recording, critically examining and
developing a new method, the inspection time is
reduced to four minute,ie a 32% saving.
MAC-Inspn of catalyst in a converter-
original method
MAC-Inspn of catalyst in a converter-
Improved method
3.ii.F TEMPLATE MODELS
Template models are used to study the
layout and the positioning of various
machines by pasting templates on the
plant layout diagram.
This can be extended by using the string
diagram technique to visualize the flow of
the material.