WORK MEASUREMENT KNOWLEDGE

SHARING:
Time Study Basics and Timer Pro Basics
Albert Serote | APC by Schneider
Electric | IT Business | PH
Industrial Engineer

References:
- Work Study International Labor Office Geneva
- Industrial Engineering Handbook - Maynard
- Doc. No. PR001B
http://dis.schneider-electric.com/Global/DDi/DIS/EN/SiteMgr.nsf/Hom

OBJECTIVES

To gain common understanding on the way P1F conducts time study.

To be able to establish, maintain, and update XMN Manufaturing
Standard Time.
To be able to use basic Timer Pro operation for time study.

TOPICS

TIME STUDY BASICS

HOW TO CONDUCT TIME STUDY

VIDEO ANALYSIS TOOL: TIMER PRO

OTHER CLARIFICATIONS

Time Study Basics

WHAT IS TIME STUDY?

is a method of recording the times for

the elements of a specified job carried
our under specified conditions, and for
analyzing the data so as to obtain the
time necessary for carrying out the
job at a define level of performance.

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Work measurement techniques

The choice of the methodology will depend mainly on:

-

the operation cycle time

the volume of identical or similar parts or products manufactured

Self recording, Compare-Estimate, Activity sampling, Stopwatch time study and Video-analysis are retrospective methods in that the jobs must be seen
Micro or Macro Standards are prospective methods as they can be used for timing jobs before they start.

The method level (Micro-standard to Macro-standard) will depend on the operation cycle time and repetitiveness:
- the method level is the quality of a work routine dependent upon the skill of the respective individual and
the organizational degree of the work system.

High
method
level

Pre-engineered
Products
Processes

Low
method
level

Engineered
To Order
Processes

Work measurement techniques

Self recording : time noted on product or work-order tracking sheet

useful for efficiency tracking, assessing work and to group similar products/processes into families
not recommended to develop standard times

Compare Estimate : time noted from comparison of similar product or process or estimated by the analyst from knowledge and practical
experience of work
- useful for efficiency tracking, assessing work and to group similar products/processes into families
- not recommended to develop standard times

Activity sampling : time noted from statistical technique that can be used as a means for collecting data. A technique in which a large number of
observations are made over a period of time of processes or workers, the statistical error depends on the size of the sample.
not recommended unless there is no other method available at the time

Stopwatch time study : the observer time each element and each timing is rated by the pace at which the operator was working. It is subjective,

not reproducible, has a low confidence and one needs a long time for training.
could be useful for standard time definition in running production but require well trained engineers
not recommended unless there is no other method available at the time

Video-analysis : time noted from video recording of work method using computerized study board.
- could useful to create macro-standard data when used with a rating system and when products are produced on an infrequent basis
recommended for Make to Order or for Engineered To Order products

Micro-standard data : predetermined motion time system as Method Time Measurement. Effective for developing standards for highly repetitive
tasks that have relatively short cycle time.
- recommended for pre-engineered products in batch or mass production

Macro-standard data : describe the time data for a compilation of group of motions. They take advantage of similarities of activities within like
-

families of operations and uses those similarities to develop standards for related activities.
recommended for Make to Order or for Engineered To Order products

TWO METHODS OF TIMING

Fly

back or snap back timing - the timer is returned to

zero at the end of each element and are allowed to start
immediately for the following element. This is generally
used for all time studies.

Cumulative

timing - the timer runs continuously

throughout the study. It is started at the beginning of the
first element of the first cycle to be timed and is not
stopped until the whole study is completed. The individual
element times are obtained by successive subtractions of
the time for each element after the study is completed.
This method is generally used to ensure that all the time
during which the job is observed is recorded in the study.
However, this includes non-standard activities, elements,
downtimes, and un-necessary movements of the operator.

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THE ELEMENT

is a distinct part of a complete

work cycle of a specified job
selected for convenience of
observation, measurement, and
analysis.
Work Cycle - is the sequence of
elements, which are required to
perform a job.

TYPES OF ELEMENTS
Repetitive

element - occurs repetitively in every work cycle of the job.

Example: screwing, insert, paint marker, rivet
Occassional/incidental element - occurs occassionally in every work cycle
of the job at regular or irregular interval.
Example: Fill-up ticket, attach sticker
Constant element basic time remains constant whenever it is performed.
Example: Burn-in time, cure time
Variable element - basic times varies in relation to some characteristics of
the product, equipment, or process.
Example: External visual inspection
Manual element - element performed by a worker
Example: Fill-up ticket, get lot, load wafer.
SPS TERM: Tm manual time
Machine element - element automatically performed by a machine
Example: Burn-in , screen print
SPS TERM: Tt technological time
Man-Machine element semi-automatically performed by a machine, but
with the aid of a worker
Example: Manual Test, forklift operation
SPS TERM: Ttm techno-manual time
Foreign element - element observed during the study which, after the
analysis, is not found to be necessary part of the job.

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CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS

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MANUFACTURING STANDARD TIME

The standard time is the time required by an average skill worker,
working at a normal pace, to perform a specific task using a prescribe
method, allowing time for personal needs, fatigue and delay.
Time standards are always related to work standards & work instructions.

An average skill worker is an operator who is representative of the

people performing the task, someone who is skilled in the job and can
perform it consistently throughout the entire day.

The normal pace is a rate of work that can be maintained for an entire
work day.

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How to conduct Time Study

CONDUCTING THE TIME STUDY

DATA GATHERING
- Gather all information for the part number or stock keeping units (SKU) to
be studied. This should be use as the basis and initial information on the
product specifications and availability status.
SELECT APPROPRIATE JOB CONDITIONS
- Only qualified operators should be studied. This operator should have
sufficient training, education and demonstrated level of skill and effort to
perform at an acceptable level with respect to both quantity and quality.
Only qualified operators should be studied. This operator should have
sufficient training, education and demonstrated level of skill and effort to
perform at an acceptable level with respect to both quantity and quality.
-Machines should be qualified and working according to its function.
-Process should have been established and documented thru acceptable,
understandable, and approved work instructions.
-Materials are readily available and qualified for the operation.
-Acceptable layout, fixtures, and tools ready for use.

CONDUCTING THE TIME STUDY

SELECTING THE TIME STUDY TECHNIQUE
- Techniques are chosen based on company requirement, applicability,
urgency, and general purpose.
STUDY THE PROCESS
- One should familiarize himself to the process, sequence, and location of
the Job in order to do the time study.
BREAKDOWN OPERATION INTO ELEMENTS
- Operation should be broken down into elements, in this way, certain
purposes could be accomplished as a result of a well broken down
operation. As such purposes are, lean classification, line balancing,
improvements, comparison, and a well understanding of the details for
those who would be succeding to continue or maintain the time study
itself.

CONDUCTING THE TIME STUDY

DECIDING ON THE ELEMENTS
-Work elements selected should correspond to a standard work method that
has been
running smoothly for a period of time in standard work environment.
-Elements should be easily identifiable, with definite beginnings and endings
known as "breakpoint".
-Elements should be as short as can be conveniently timed by the observer,
generally considered to be about 2.4 seconds.
-Incidental operations should be identified and separated from the repetitive
work.
-Should be identifiable for lean classification (VA, CNVA, FNVA, Tt, Tm, Ttm)
SAMPLE SIZE
-Number of observations sample size can be reduced if practical trend of
time were observed and established.

SETTING THE STANDARDS

NORMAL TIME is the time it would take by a qualified worker to carry out
the element at standard rating or at normal pace.
NORMAL TIME = AVE. OBSERVATION TIMES X RATING FACTOR
STANDARD TIME is the time required by an average skill worker, working at
a normal pace, to perform a specific task using a prescribe method, allowing
time for personal needs, fatigue and delay.
FREQUENCY is the number of occurrence of a specific element in every
work cycle (every lot) of the operation.
PFD ALLOWANCE is personal, fatigue, and delay allowance. We use the
International Labor Office table for reference.
STANDARDS = NORMAL TIME X FREQUENCY X PRD ALLOWANCE

SETTING THE STANDARDS

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Good practice in Video-analyze

By Viswanathan Muthuraman method engineer

& Ashish Adhikari
Head - Operational Excellence APC Bangalore

Work load Analysis : No. of SKUs - 400 Finished Goods + 500 PCBs
for this many unit the time study has to be done
Effect of process changes & Improvements : When any process change or improvement is happening, as the time
study is manual, we have to repeat the whole time study again.
This makes the process cumbersome.
This initiated to search for an alternate option.
The objective is, using the alternative option the IE Engineer
should be able to do the study from his table and all other calculations
should be automatic and line balancing should be done using
drag and drop method. When an improvement is happening
only that element / process should be able to modify

Alternate Option selected was to do a Video Time study using a software

including video and time measurement

Details of Video Time study Software

Name of the Software :
Timer Pro
Software owner
:
ACSCO
Website
:
www.acsco.com

nalyzing process in Software, main controls

Data
collected

Video
Display

Activity
description
Video play
control & info

Snap shot
capture

Activity list
File control

Sample Reports Stage Summary report

Sample Reports Line balance reports

More options are available for analysis

Line balancing

VA / NVA

Pareto

Ergonomics

Final standard report

Allowances

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Schneider Production System

3 Added Value / Non Added Value
identification

muda
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Added Value for "Pre-Engineered Product"

Pre-engineered products are standard product and sub-assembly displayed in the
Schneider catalogue
The manufacturing operations are repeated few times a day, The assembly learning time is quite short and the operator should not
have to refer to specifications every cycle.

Are considered as increasing the product value: all elements or motions done within the
comfort or acceptable ergonomic zones as defined in the Schneider ergonomic handbook,
and concerning the following operations :
manual or assisted assembly
.
adjustment and electrical or mechanical normative test
labeling and customer packaging before shipment
The issuer of the order is considered as the customer of the line

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Non-Added Value for "Pre-Engineered Product"

Tasks not included in the Useful Time and considered to have no added value:
Every hand motion outside of the ergonomic zones as defined in the Schneider ergonomic handbook.
Each time an operator walks out the U shape line (procurement, evacuation, etc.).
Each time an operator moves from one workstation to an other one
Visual inspection for compliance, operating inspection (requested by the designer), and auto-inspection
(Compliance inspection is a specific action to check whether the assembly has been carried out correctly).

Reading drawings or filling out administrative documents (start-up, recording, etc.).

Tasks associated with work organisation (co-ordination, change over time, inventories, work station cleaning,
maintenance, etc.)

Frequential elements, re-packing and labelling of parts required by the process

Quality actions (sorting parts, treating rejects, repairs, etc.).
Operator waiting time
Physiological resting time

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Elasticity is required , because the line capacity should be rapidly adjusted to the variation in the customer orders received.
Sometime the operators should move from one workstation to an other one, the time spent is not included in the Useful Time
calculation.
Useful time is calculated for a defined process. If the process is in the middle of being re-engineered, the useful time is calculated
for the new process organisation. Do not define a Useful Time based on potential improvements but only on real commitments
(action plan, investments, deadlines for its implementation).

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Normative Inspection
The following inspections are considered as normative and value added:
Inspection carried out according to the product norms (CEI, UL, NEMA ).
Example : low voltage or
high voltage insulation test
Operating inspection : running test designed and applied according to the customer requirements. Example : test of the
product driver circuit according to the customer requirements
Those operating times are included in the Useful Time calculation

Inspections which are considered to have no added value:

Visual inspection for compliance and auto-inspection
(Compliance inspection is a specific action aimed at checking to see whether the assembly or the customer order has been carried out
correctly).

Operating inspection for internal processes requested by:

- Marketing
-R&D
- Advanced manufacturing

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Theoretical breakdown of manufacturing labor time

Industrial Efficiency IE = Useful Time / Time spent

absenteeism

DVC

Difference = TS - UT

services

Uncertainti
es
Non
Quality
DCV

Frequential
elements
Cyclic
elements

Useful
Time

Waste generated by running

the process

Paid hours

activity

Time Spent

Operator

external to
process

Non value added

characteristic of the
process design

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Theoretical breakdown of manufacturing labor time

Useful
Time

Cyclic
non VA

Frequential
non VA

Operator
Activity

DVC
External to
Process

Non
Quality

Uncertainties

Pre-engineered products:
- Value-added manual assembly operations
- Motions inside of the ergonomic zone (parts or tools) (see slide 28 & 29)
- Normative controls or controls required by customer
- Packaging before shipment

Useful
Time

Cyclic
non VA

Frequential
non VA

Operator
Activity

DVC
External to
Process

Non
Quality

Uncertainties

Engineered-To-Order products :
- same definitions than pre-engineered product
- + reading drawings or documentation useful for the product assembly
- + fill in administrative document to be sent to customer
- + picking and packaging parcel to be sent to customer

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Theoretical breakdown of manufacturing labor time

Useful
Time

Cyclic
non VA

Frequential
non VA

Operator
Activity

DVC
External to
Process

Non
Quality

Uncertainties

Cyclic elements (sequential actions proportional to the volume) :

- Motions outside of the ergonomic zone (see slide 28 & 29)
- Moving outside of the working zone (procurement, taking parts from the line, )
- Quality non-normative control, visual control included in the PQCP.
- Non value-added cyclic element or operation
- Cyclic administrative task conducted by direct workers
- Operating waiting time
- Physiological rest
Useful
Time

Cyclic
non VA

Frequential
non VA

Operator
Activity

DVC
External to
Process

Non
Quality

Uncertainties

Frequential elements (sequential actions proportional to "n" cycles) :

- Procurement or removal of products or parts
- Sampling quality control
- Batch label printing
- Non value-added sequential element or operation
- Non cyclic administrative task conducted by direct workers

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Value added Zone for Pre-engineered products assembly

Green zones (acceptable & comfort zone) are considered as Value Added Zone
Arduous zone

Acceptable zone

Acceptable zone

290
( 11)

Comfort zone

Comfort zone

90
100 ( 4)

250 ( 10)

250 ( 10)
1170 maximum
( 46)

80cm

80cm

Product

80cm

Value Added Zone

80cm

Parts

Parts

Value Added Zone for ETO processes

Value Added Zone for ETO processes

Arduous
zone

Acceptable
zone

Comfort
zone

Green zones (acceptable &

comfort zone) are considered
as Value Added Zone

1600
( 63)

800
( 32)
Arduous
zone

1500
( 59)

THANK YOU VERY MUCH