ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

Application of a Stopwatch Time Study (Two Milling Machines)

1. Introduction
In this lab, the instructor or teaching assistant will operate two milling machines, while the students perform time study analysts. The students will suggest improvements to the task. You may be watching a film of the operations instead of live operations. If the operations are live, make sure you observe all safety precautions listed in the Safety Regulations Module.

2. Demonstration of the Operation of Two Milling Machines

2.1. Introduction The instructor will explain definitions, assumptions, and conditions regarding the milling task. The students will be doing their own breakdown for this task. The instructor will then review their element breakdowns. 2.2. Demonstration The instructor or teaching assistant will demonstrate a task, which is the operation of two milling machines at the same time by a single operator.

3. Student performance of the suggested task

The report will be submitted as a group report. Attach a one-page description of each members contribution to the report. The grade for each member of the group will vary according to the description so that the description must be detailed enough to determine which member contributed which part. As a group, assign tasks and sections of the report to each member effectively and show the process in the description. The time study analysts must watch the instructor or teaching assistant throughout the training period, in order to learn the work method and determine the work elements and the start/stop points. Students may find anywhere from 6-8 elements or more, depending on how they decide to break down the task. The time study analysts will use the continuous method to time the worker. When the instructor has performed several cycles of the task and each analyst has defined his/her element breakdown and the start/stop points, the students should time and record 3-4 overall cycle times. Then the students should time ten complete cycles, using the element breakdowns and recording the times on the time study form in section 7. The ratings to be used for the various elements, allowances, auxiliary elements, and other task details are provided in section 7.

ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

4. Report Requirements
4.1. Run time/piece (4pts) Calculate the run time for each machine per blank, given that the approach and over travel are 1.5 inches on both sides for each machine. 4.2. Production rate/shift (4pts) Calculate the production rate per shift, given the performance ratings in section 7.1, the allowances in section 7.2, the auxiliary elements in section 7.3, and the setup/cleanup times in section 7.4; i.e., calculate the number of parts or pieces produced per shift. 4.3. Effective use of two machines (4pts) To effectively have one operator run both machines, we need to make the run time identical (why?). Present at least two ways this could be accomplished. 4.4. Element definition (4pts) In your lab report, be sure to clearly define each of your elements, which include identifying the break point of each element when you make a stopwatch reading. 4.5. Time study form (4pts) Present your complete time study form. 4.6. Suggested improvements (6pts) Suggest improvements to the current method for operating the two milling machines. 4.7. Dixon Test (4pts) Do the Dixon test on all element times.

5. KeyTerms
Continuous Timing Method Snap Back Timing Method Allowances

ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

6. References
Barnes, R. M. (1980). Motion and time study. (7th ed.). New York: John Wiley & Sons, Inc. General Motors Institute. (1972). Methods analysis and work measurement. Detroit, MI: Industrial Engineering Department. Konz, S. (1983). Work design: Industrial ergonomics. (2nd ed.). Columbus, OH: Grid Publishing Co. Mundel, M. E. (1978). Motion and time study. (5th ed.). Englewood Cliffs, NJ: Prentice Hall, Inc. Niebel, B. W. (1982). Motion and time study. (7th ed.). Homewood, IL: Irwin, Inc. Salvendy, G. (Ed). (1982). Handbook of industrial engineering. New York: John Wiley & Sons, Inc.

7. Appendix
7.1. Performance Ratings Apply performance ratings of 105% to the first two elements, 90% to the next two elements, and 100% to the remainder of the elements. 7.2. Allowances 5% - personal needs 10% - fatigue 10% - unavoidable delays 7.3. Auxiliary elements 1. 2. 3. 4. 5 minutes per 100 blanks to procure tote box of raw materials 3 minutes per 100 blanks to dispose of tote box of finished materials 30 minutes per 200 blanks to change and adjust both cutting tools 1 minute per 40 blanks to clean both milling machines

7.4. Setup/Cleanup 1. 2. 15 minutes per day to get ready 10 minutes per day to clean up

7.5. Equipment and material specification 1. 2. tote box of 2" x 3" x 3/16" SAE 1020 steel blanks tote box for finished pieces 3

ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

7.6. Time Study Forms

Elements

Date ______ Study # ______ Sheet # ___/__ Foreign Elements Description

Element # Cycles

Cycle Time

Sym

Total # of Obs Avg Time Perf Rating Normal Time Freq Allowed Time

A B C D E F G H I J K Total Allowed Time PFD Allowance Std Mins per Pc Std Pcs per Min Time Check Study Study Started Finished

Overall Time

Analyst:

ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

Elements

Date ______ Study # ______ Sheet # ___/__ Cycle Time Foreign Elements Description

Element # Cycles

Sym

Total # of Obs Avg Time Perf Rating Normal Time Freq Allowed Time Remarks

A B C D E F G H I J K Total Allowed Time PFD Allowance Std Mins per Pc Std Pcs per Min Time Check Study Study Started Finished

Overall Time

Analyst:

ISE 3014 Work Measurement and Methods Engineering, 2005 Fall

Study # ______ Sheet # ___/__ Element # Cycles Cycle Time Foreign Elements Description

Sym

Total # of Obs Avg Time Perf Rating Normal Time Freq Allowed Time Remarks

A B C D E F G H I J K Total Allowed Time PFD Allowance Std Mins per Pc Std Pcs per Min Time Check Study Study Started Finished

Overall Time

Analyst: