Method Study

Introduction to Method Study

It is a scientific technique of observing,

recording and critically examining the present method of
performing a task or a job or an operation .
Objectives of method study
• To develop an improved method to improve productivity
and to reduce operating cost.
• To reduce excessive materials handling or movement and
thereby reduce fatigue of workmen.
• To improve utilization of resources.
• To eliminate wasteful and inefficient motions.
• To standardize work methods or processes, working
conditions, machinery, equipments and tools.
Advantage of method study:
1.Work simplification
2.Improved working method (cheaper method)
3.Better product quality
4.Improved workplace layout
5.Improved equipment design
6.Better working conditions/environment
7.Better materials handling and lesser materials handling cost
8.Improved work flow
6. Less fatigue to operator
7. Optimum utilization of all resources
8. Higher safety to workmen
9. Shorter production cycle time
10. Higher job satisfaction for workmen
11. Reduced material consumption and wastages
12. Reduced manufacturing cost and higher productivity.
Factors facilitating method study
• High operating cost
• High wastage and scrap
• Excessive movement of materials and workmen
• Excessive production bottlenecks
• Excessive rejections and rework
• Complaints about quality
• Complaints about poor working conditions
• Increasing number of accidents
• Excessive use of overtime .
Method study procedure
The various steps involved are
1.Select:
Study the job , define the objective and achieve by
method study
2.Record:
Record the relevant facts to the existing methods using
the following techniques
a. Process charts
b. Diagrams
a. Process charts
1. Outline process charts
2. Operation process charts
3. Flow process charts
4. Man-machine type
5. Two handed process chart
6. Multiple activity chart
7. Simultaneous motion chart(SIMO)
8. Motion chart
9. Film analysis chart
b. Diagrams
1.Flow diagram
2.String diagram
3.Cycle diagram
4.Chronocyclegraph
3.Examine
The recorded facts critically ,challenging everything
being done and seeking alternatives ,Questioning the purpose
(what is achieved?) , the means ( how it is achieved?) ,
sequence (when is it achieved?) , the place (where is it
achieved?) ,and the person (who achieves it?).
d. Develop
Develop the improved method by choosing from different
alternatives .The factors to be considered
are
•Cost of implementation
•Expected savings in time and cost
•Feasibility and Producibility
•Acceptance to design , production ,planning and control,
quality control , production and sales departments
•Reaction of employees to the new method
•Short term or long term implication of the alternative
e. Install
Install the new method which consists of 3 phases
1.Planning
2.Arranging
3. Implementing phases.

f. Maintain
Maintain the new method by checking its
performance and verification at regular intervals
 Worker flow study / Motion study

It is the science of eliminating wastefulness ,main aim is

to find and perpetuate the scheme of the least waste method of
labour .
Micro motion study provides a valuable technique for
making minute analysis

E.g., Sewing of garments , assembling of small parts.

Fatigue ,Find.
It is also used for,
a.To study the inter-relationship among the members of
work group .
b. To study the relation between operator and the machine
with which he operates
c. To obtain the time of operation
d. To establish a permanent record of the method of doing a
job.
 The study is done in 3 steps
a.When the motion begins
b.The nature of the motion
c.When the motion ends.
E g: Search , Select , Grasp , Transport Empty, Transport
Loaded, Hold , Release Load , Position , Preposition,
Inspect, Assemble , Disassemble , Use ,Unavoidable delay ,
Avoidable delay, Plan , Rest of overcoming.
 Work Measurement
This is done to achieve higher labour productivity
Definition
Application of technique designed to establish the work
content of a specified task by determining the time required
for carrying out the task at a defined standard of performance
by a qualified worker.
Qualified Worker:
One who is accepted as having the necessary physical
attributes , required intelligence , education, skill , knowledge
to carry work in hand to satisfying standard of safety ,quantity
and quality defined by ILO ( International Labour
Organisation)
Objectives :
• Improved planning and control of activities or
operations
• More efficient way to provide labour in a plant
• Reliable ideas for labour performance
• Reliable basis for labour cost control
• Basis for sound, incentive -Schemes
Benefits of Work measurement
• To develop a basis for comparing alternate methods .

• To prepare realistic work schedules by accurate assessment

of human work

• To set standards of performances for labour utilization

• To compare actual time taken by the worker with the

allowed time (standard time) for proper control of labour.
• To assist in labour cost estimation
• To provide information related to estimation of tenders,
fixation of selling price and assessment of delivery schedule.
Techniques of work measurement:
1.Direct Time study
2.Synthesis method
3. Analytical estimating
4.Pre – determined motion time study (PMTS)
5. Work Sampling or Activity Sampling or
Ratio delay method.
Steps in work measurement:
1.Break the job into elements.
2.Record the observed time for each element by means -of
either time study, synthesis or analytical estimating
method.
3.Establish elemental time values by extending observed
time into normal time for each element by applying a
rating factor.
4.Assess relaxation allowance for personal needs and
physical and mental fatigue involved in carrying out
each element.
5.Add the relaxation allowance time to the normal time for
each element to arrive at the work content.
6.Determine the frequency of occurrences of each element
in the job, multiply the work content of each element by
its frequency (i.e., number of time the element occurs in
the job) and add up the times to arrive at the work
content for the job.
7. Add contingency allowance, if any, to arrive at the
standard time to do the job.
Time study:

To determine amount of time required to perform a unit

of work.

Definition:

ILO – “ Time study is a work measurement technique for

recording times and rate of working for the elements of a
specified job carried out under specified condition and for
analysing The data so as to obtain the time necessary for
carrying out the job at defined level of performance.
Objectives:

a)To furnish a 'basis of comparison for determining operating

effectiveness.,
b)To set labour standard for satisfactory performance.

c)To compare alternative methods in method study in order

to select the best method.
d)To determine standard costs.

e)To determine equipment and labour requirements

f)To determine basic times/normal times.

g)To determine the number of machines an operator can
handle.
h)To balance the work of operators in production or
assembly lines

i)To provide a basis for setting piece rate or incentive wages

j)To set the completion schedules for individual operations

or jobs.

k)To determine the cycle time for completion of a job.

Time study by stop watch:

The steps involved are

1.Select the job to be studied

2.
3.Select the worker to be studied
4.
5.Conducting the stop watch time study.
Select the job to be studied

1.New job taken for production.

2.Change in manufacturing method.
3.Design change.
4.Change in raw material or components used for a job.
5.Complaint about inadequacy of allowed time.
6.For bottle neck operations.
7.When labour cost is high.
8.To establish standard time a “a basis for incentive
scheme” .
9.When new tools, jigs and fixtures are used.
Select the worker to be studied
Ideal worker is “Qualified Worker”

Conducting the stop watch time study.

a.Obtain & record all the information about the job, operator
& working condition
b.
c.Record the method of doing the job & break down the job
into elements
d.
Various elements are,
1.Repetitive element
2.Occasional element
3.Constant element
4.Variable element
 5.Manual element
6.Machine element
7.Governing element
8.Foreign Element
Examine the elements to ensure that the element to ensure
that the most effective motions are used in the elements of
job performed. Measure the actual time taken by the operator
each element of the job, using a stop-watch.

Stop watch is of 3 Types

1.Non Fly Back

2.Fly Back
3.Split hand
Asses the effective speed of working of the operator with
respect to the time study observer concept of the speed of
working of a qualified worker who is assumed to have a
standard rating
Rating factor or leveling factor is determined by comparing
the actual pace or speed of working with the standard pace
or speed of working ( Of a qualified worker)

Rating scales : Three types

1.60 – 80 Scale
2.75 – 100 Scale
3.100 – 133 1/3 Scale
Rating assigned in the scale Level of performanceCorresponds to
60-80 75-100 100-1331/3 walking speed
0 0 0 No activity Nil

40 50 67 Very slow, clumsy, no 2mph

interest to do the job
60 75 100 steady, unhurried 3mph
performance
80 100 1
133 /3 Businessmen- like, 4mph
brisk, performance of a
100 125 167 Very fast, worker
qualified incentive 5mph
motivated

Rating of the observed worker

Rating Factor =
Rating of the qualified worker
Determination of normal or basic time:

Normal or basic Time = Observed time X Rating factor

Observed Rating
= Observer time X
Std Rating

Determine the relevant allowances

1.Relaxation allowances (RA)
2.Contingency allowance(CA)
3.Process allowance
4.Special Allowance
Determine the standard time by adding the relevance
allowances to the normal or basic time

Std time = Normal time + all relevant allowances

Synthesis Method

Technique of work measurement for building up the time

required to do a job at a defined level of performance by
synthesizing or totalling elemental time values obtained
from previous time studies or other similar job elements

Std Data

Catalogue of “Normal” or “Basic” time values for different

elements of job
Advantages of Synthesis Method

1.Reliable as the built-up time values of the 'standard data'

catalogue, are based on data derived from a large
number of time studies.
2.
3.Economical as less time is required when compared to
'stop-watch' time study
4.
5.Used for estimating labour times for preparing cost
estimates for new jobs for which the selling price has to
be quoted to customers.
 Application

1.To estimate standard time for new jobs

2.
3.To estimate production time for determining the prices
of products to be sold

4.Used as a basis for designing incentive schemes.

Analytical Estimating
Used to determine the time values for job having long and
non repetitive operations
 Procedure of Analytical Estimating
(a)Find out the job details such as job dimension, standard
procedure to do the job, and the job conditions, such as
poor illumination, high temperature, hazardous
environments, . availability of jigs, fixture or tools, etc.,
(b)
(b) Break the job into its elements

(c) Select time values from the standard data catalogue for
as many elements as possible. (i.e,. use synthetic data
wherever available)

(d) Estimate the time values for the remaining elements

(for which synthetic data is not available) from past
knowledge and experience
(e) Add the time values obtained by steps (c) and (d) to get
the total 'Basic‘ or 'Normal' time (for 100% rating)

(f) Add the appropriate blanket relaxation allowance (say

10% to 20% of total normal or basic time). Note that in
analytical estimating, the relaxation allowance is not added
to time values of individual elements. The blanket
relaxation allowances-depends on the type of the job and
the job condition.

(g) Add any other allowances if applicable, to arrive at the

standard time for the given job.
Advantages of Analytical Estimating Technique

(a)Offers the same advantages enjoyed by synthesis

method.
(b)
(b) Helps in planning and scheduling the production.

(c) Provides a basis for fixing the labour rate for non-
repetitive jobs.

(d) Steps to improve labour control

Disadvantages

This relay upon the judgment of the estimator, the time

values obtained may not be as accurate and reliable as that
estimated by the stop watch time study

Applications of Analytical Estimating Technique

1For non-repetitive jobs, jobs having long cycle times and

jobs having elements of variable nature. For such jobs
the stop-watch time study proves to be uneconomical.
2For repair and maintenance work, job production, one
time large projects, office routines, tool room jobs and
engineering construction works.
Predetermined Motion Time System (PMTS)

Defined as a work measurement technique by which normal

or basic times are established for basic human motions and
these time values are used to build up the time for a job at a
defined level of performance

Advantage of PMTS

1.Affords fine analysis and improvement of work methods.

2.
3.Since the time for each basic motion is predetermined. the
computation of standard time for a job or an operation is
faster and more economical than time study using stop
watch.
3.Offers a precise means of recording time, avoiding
subjective judgment or bias of the rater.
4.
5.Involves no interference in the normal work routine and
hence faces little resistance from workers
6.
7.More effective and economical tool for work
measurement for repetitive jobs of short duration.

Disadvantages
1.
2.Such standards are not available for each and every
human activity
3.Limited to only uninhabited work in its application, i.e.
for the work whichdoo8 not involve motions, restricted
by the process
3.Has limited application in non-repetitive and office
activities.
4.
5.Fairly long period of intensive training under expert
guidance is necessary to use this technique.

Types of Predetermined Motion Time Systems

1Methods of Time Measurement (MTM) :

In this method, predetermined time values for basic

motions or therbligssuch as reach, move, turn, apply
pressure, grasp, etc.. are established in terms of TMU's
(i.e. Time measurement Units).
1tmu = 10-5 hours
= 0.00001 hour or 0.0006 minutes or 0.036 seconds

Application of MTMs Techniques

1.Developing effective methods in advance of beginning the

production.
2.Improving existing methods
3.Establishing standard time data
4.Estimating labour time and cost.
5.Training supervisors to be method conscious.
6.Choosing between alternative methods.
ii. Work Factor

It is based on basic motions which are modified elements of

difficulty, all of which tend to make movements slower.
These features or work factors are weight or resistance,
change of direction, need for care, stopping a motion &
manual control, each of these features is known as a “Work
Force”

iii. Basic Motion Times (BMT)

The times were derived from laboratory experiments & were

carefully checked against a variety of factory operation
before being accepted for general use. BMT data is based on
basic motions
Basic motions are classified as : figure, hand and arm
motions

Class A – Without use of muscular control in stopping the

motion
Class B – Stop using muscular control
Class C – stop by use of muscular control both to slow down
the motion

5. Work Sampling or Activity Sampling or Ratio Delay

method

The random samples the work of one or more employees are

periodic interval to determine the proportion of total
operations that is accounted for in a particular activity
Use of work sampling technique

1.To estimate the percentage of a protracted time period

consumed by various activity states of a resource
such as equipment, machines or operators.
2.
3.To determine the allowances for inclusion in standard
times.

4.To indicate the nature of the distribution of work

activities within a gang operation.

5.To estimate the percentage of utilization of groups of

similar machines or equipment.
5.To indicate how materials handling equipments are Ming
used.
6.
7.To provide a basis for indirect labour time standards.
8.
9.To determine the productive and non-productive
utilization of clerical operations.
10.
11.To determine the standard time for a repetitive
operation as an alternative to the stop
Work sampling procedure

The works study engineer takes a great number of

observation of a worker / machine random times
throughout the working shift or day

The technique is based upon the laws of probability

X No of observations of the activity

P= =
N Total no of observations
Steps in work sampling
1.Determine the objective of the study, including definitions
of the states of activity to be observed.
2.Plan the sampling procedure including:
a)An estimate of the percentage of time being devoted
to each phase of the activity
b)The setting of accuracy limits
c)An estimation of the number of observations
required
d)The selection of the length of the study period and
the programming of the number of readings over
this period
e)The establishment of the mechanics of making the
observations, the route to follow and the recording
of data
3.Collect the data as planned.
4.Process the data and present the results.
 Principles of work sampling
C2 PQ
C2 P(1-P) C2 P(1-P)
N= Or Or 2
(SP)2 E 2 E

Where

P -> Percentage or true proportion of activity or idling

which is being observed based on pilot study

S -> Relative error of the true proportion “P”

C -> Constant values 1, 2 & 3 corresponding level of

68.3%, 95% and 99% respectively
Advantages of Work Sampling
1.Economical to use and Usually costs considerably less
than a continuous time study
2.Can be used to measure many activities that are
impractical to measure by time study
3.Not necessary to use a trained work measurement analyst
to make the observations.
4.Work sampling measurements may be made with a pre-
assigned degree of reliability
5.Measures the utilization of people and equipment directly
6.Eliminates the necessity of using stop-watch for
measurements.
7.Provides observation over a sufficiently long period of
time to decrease the chance of day to day variation
affecting the results
Limitations of Work Sampling

1.It is of little value in helping to improve work methods

and does not offer some of the opportunities for methods
analysis that accompanies time study methods.
2.
3.Statistical work sampling may not be understood by
workers

4.If random sampling is not done, the results may be biased.