Method Study

Flowcharting

Company
LOGO
 Outline

1.
1.Work
WorkStudy
Study

2.
2. Method
Method Study
Study

3.
3.Various
Various Charts
Charts

February 2, 2017 Lab # 6: Method Study 2

 Work Study
Work Study is a generic term for management
services and system engineering techniques,
used to investigate:

Methods of performing work (Method Study).

The time taken to do it (Work Measurement).

February 2, 2017 Lab # 6: Method Study 3

 Work Study (Cont.)

February 2, 2017 Lab # 6: Method Study 4

 Method Study
Method study is a technique to reduce the work
content mainly by eliminating unnecessary
movements by workers, materials, or equipments.

However, even after that, there could be substantial

unnecessary time taken for the process because of
lack of management control or inaction of worker.

Method Study approaches and tools of Method

Analyst:

Flow Diagrams & Process Charts etc.
Critical questioning techniques.

February 2, 2017 Lab # 6: Method Study 5

 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.
Used to analyze
Movement of body, people, or material
Activities of people & machines

February 2, 2017 Lab # 6: Method Study 6

 Method Study Objectives

Improvement of processes and procedures.

Improvement in the design of plant and equipment.

Improvement of layout.

Improvement in the use of men, materials and

machines.

Economy in human effort and reduction of

unnecessary fatigue.

Development of better working environment.

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 Method study -
Methodology
Procedure to accomplish method study, called
"SREDIM" shall be as follow:
1. Select: the job or operation that needs improvement,
2. Record: all facts, how work is done by chart
methods,
3. Examine: every aspect of the job by asking; what,
why, where, when, who and how
4. Develop: review ideas, eliminate, simplify, combine,
re-arrange, make new method which more safe, chart
new method, submit for approval,
5. Install: the new method, consider best time to
introduce, convince all, train users,
6. Maintain: check frequently, match results, correct
deviations.

February 2, 2017 Lab # 6: Method Study 8

 Methodology (Cont.)
Select
Recor
d
Exami
ne

OK
?

Develo
p
Install
Maintai
February 2, 2017 n Study
Lab # 6: Method 9
 Method Study Tools

Exploratory Tools
Pareto Analysis
Fish & Bone Diagrams
Gantt and PERT charts
Recording and Analysis Tools
Operation Process Chart
Flow process chart
Flow diagram
Worker and Machine Process Charts
Gang Process charts
Synchronous Servicing

February 2, 2017 Lab # 6: Method Study 10

 Method Study
Applications
The need for methods analysis can come
from a number of different sources :
Changes in tools and equipment.
Changes in product design or new products.
Changes in materials or procedures
Other factors (e.g. accidents, quality problems)

February 2, 2017 Lab # 6: Method Study 11

 Recording
Techniques
Charts
1. Outline process chart.
2. Flow process chart (man-type, material-type and
equipment-type): This is the use of symbols and
description to chart the sequence of work. The process,
then, show what is happening at different
stages. The distances and time may be given.
3. Two hands process charts.
4. Multiple activity charts: This technique is used to
solve problems where a number of items are dependent
on each other. The aim is to reduce idle times by using
the optimum number of each item. It depicts the
occupied times-broken down into the number of
different activities and the idle times both for the
original and proposed methods of doing the job.

February 2, 2017 Lab # 6: Method Study 12

 Recording
Techniques (Cont.)
Diagrams and models (2-D and/or 3-D)
1.Flow diagrams, which is the use of symbols for
flow process charts, superimposed on drawings
and the "descriptions" are not necessary.
2.String diagrams, which is used for solving
movement problems since it shows congestions
and excessive distances.
3.Cut-out templates (2-D models).
4.3-D models.
Photography
1.Photographs,
2.Films,
3.Video.
February 2, 2017 Lab # 6: Method Study 13
 Assembly Chart
It is an analog model of the assembly
process.
Circles with a single link denote basic
components, circles with several links
denote assembly
operations/subassemblies, and squares
represent inspection operations.
The easiest method to constructing an
assembly chart is to begin with the original
product and to trace the product
disassembly back to its basic components.

February 2, 2017 Lab # 6: Method Study 14

 Assembly Chart (Cont.)

Assembly Chart for prod

ucing Cheese Hamburger

February 2, 2017 Lab # 6: Method Study 15

 Assembly Chart (Cont.)

February 2, 2017 Lab # 6: Method Study 16

 Operation Process
Chart
The operation process chart shows the
chronological sequence of all operations,
inspections, time allowances, and materials
used in a manufacturing or business
process, from the arrival of raw material to
the packaging of the finished product.
The chart depicts the entrance of all
components and subassemblies to the
main assembly.
Two symbols are used in constructing the
operation process Chart : an operation
and an inspection.
February 2, 2017 Lab # 6: Method Study 17
 Operation Process
Chart (Cont.)
Operations charts show the introduction of
raw materials at the top of the chart on a
horizontal line.
Operation Pieces / Hr
Number
Hours / 1000

Some parts require no fabrication steps.

These parts are called buyouts. Buyouts
are introduced above the
Tape operation

Carton

February 2, 2017 Lab # 6: Method Study 18

 Operations Chart
Steps
Step by Step Procedures For
Preparing an Operations Chart:
Identify the parts to be manufactured and
purchased
Determine the operations required to fabricate
each part and sequence them
Determine the sequence or assembly for buyouts
and fabricated parts
Draw the operations chart as explained
Put time standards, operation numbers and
descriptions
Calculate and write down the total hours required
per 1,000 units
February 2, 2017 Lab # 6: Method Study 19
 Operation Process
Chart

Operation Process Chart f

or Refrigerator Support

February 2, 2017 Lab # 6: Method Study 20

 Operation Process
Chart

February 2, 2017 Lab # 6: Method Study 21

 Flow Diagrams
A flow diagram is essentially a flow process chart
drawn to:
1. Show the layout of a facility.
2. Show the flow of work through that area
3. Show overcrowding areas, crossing worker paths, total
travel.
4. Identify how layout can be redesigned to reduce travel,
motion, collisions, etc.
5. Store materials near where they are used.
6. Increase efficiency and safety.
Usually, the objective is to look for spatial relationships.
It depicts the probable movement of materials in the
floor plant. The movement is represented by a line in
the plant drawing.

February 2, 2017 Lab # 6: Method Study 22

 Flow Diagram (Cont.)

Buyer

75 ft.

You

February 2, 2017 Lab # 6: Method Study 23

 Flow Diagram (Cont.)

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 Flow Process Charts
A flow process chart is a chart of all the
activities involved in a process.
It is similar to an operations process chart,
except that more detail is shown by
including transportations and delays as well
as operations, inspections, and storages.
Not usually used for entire assemblies, it is
used for just one component (or operator)
Add in information on:

Operation duration (time to complete)

Distance traveled (for transport operations)
Good for showing savings of a new method.
February 2, 2017 Lab # 6: Method Study 25
 Flow Process Charts
(Cont.)

Process charts summarizes the whole

process
They are used to compare the existing and
the proposed methods
Process is observed, who, what, where,
when, and how questions are asked
Every detail is understood and the chart of
the existing situation is drawn

February 2, 2017 Lab # 6: Method Study 26

 Flow Process Charts
(Cont.)

Quantity:
Operations: Pieces per hour
Transportation: How many are moved
at a time
Inspection: How many pieces per hour
if under time standard and/or frequency
of inspection
Delays: How many pieces in a container
Storage: How many pieces per storage
unit

February 2, 2017 Lab # 6: Method Study 27

 Flow Process Charts
(Cont.)

Time in Hours per Unit

If 250 pieces are processed in an hour
then 1 unit is processed in 0.00400
hours. Record 400
If 200 units are moved in 1 minute, then
1/200 = 0.005 minutes per part, and
0.005/60 hours/part =0.00008 hrs/part.
Record 8.

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 Flow Process Types:
Product or Material type
Worker (Man) type
Machine type

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 ASME Standard
Symbols

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 Flow Process Chart
Symbols

Operation Delay

Transportation Storage

Inspection

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 Operation
Occurs when an object is intentionally
changed in one or more of its
characteristics
Usually occurs at a machine or a work
station
Drilling, Painting, Data Entry, Cutting,
Sorting, etc.

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 Transportation
Occurs when an object is moved from one
place to another
except when the movement is part of an
operation or an inspection
Using elevator, carrying, moving with
material handling devices

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 Inspection
Occurs when an object is examined for
identification or is compared with a
standard as to quantify or quality
Examine the quantity or quality, read
steam gauge on boiler, detect the
defectives

February 2, 2017 Lab # 6: Method Study 34

 Delay
Occurs when the immediate performance
or the next planned action does not take
place
Work In Process inventory waiting to be
processed, Employee waiting for an
elevator, Waiting for accumulation of a
certain quantity for packaging

February 2, 2017 Lab # 6: Method Study 35

 Storage
Occurs when an object is kept under
control such that its withdrawal requires
authorization
Bulk storage of raw material, finished
products inventory, archived documents

February 2, 2017 Lab # 6: Method Study 36

 Combined Symbols
Two symbols may be combined when two
activities are performed concurrently.

Operation and Inspection

February 2, 2017 Lab # 6: Method Study 37

 Flow Process Chart-An
Example

Flow Process Chart Exam

ple

February 2, 2017 Lab # 6: Method Study 38

 Flow Process Chart-An
Example
Process: Emergency room admission Summary
Subject: Ankle injury patient Number Time Distance
Beginning: Enter emergency room Activity of steps (min) (ft)
Ending: Leave hospital
Operation 5 23
Insert Step Transport 9 11 815
Inspect 2 8
Append Step
Delay 3 8
Remove Step Store

Step Time Distance

no. (min) (ft) Step description
1 0.50 15 X Enter emergency room, approach patient window
2 10.0 - X Sit down and fill out patient history
3 0.75 40 X Nurse escorts patient to ER triage room
4 3.00 - X Nurse inspects injury
5 0.75 40 X Return to waiting room
6 1.00 - X Wait for available bed
7 1.00 60 X Go to ER bed
8 4.00 - X Wait for doctor
9 5.00 - X Doctor inspects injury and questions patient
10 2.00 200 X Nurse takes patient to radiology
11 3.00 - X Technician x-rays patient
12 2.00 200 X Return to bed in ER
13 3.00 - X Wait for doctor to return
14 2.00 - X Doctor provides diagnosis and advice
15 1.00 60 X Return to emergency entrance area
4.00 -
16 X Check out
2.00 180
17 X Walk to pharmacy
4.00 -
18 X Pick up prescription
1.00 20
19 X Leave the building

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 Material Type -
Example

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 Man Type - Example

February 2, 2017 Lab # 6: Method Study 41

 Left-Hand-Right-Hand
Charts
Useful in analyzing the work performed by one
person at one specific workstation. As the name
implies, the chart follows the motion of the left
and right hands of one operator .
Each hand of the worker is treated as an activity.
Each hands activities are broken into work
elements and plotted side by side on a time
scale.

February 2, 2017 Lab # 6: Method Study 42

 Left-Hand-Right-Hand
Charts (Cont.)
Lists the work performed
simultaneously by each hand
To assist in finding a better method of
performing the task and
To train the operator in the preferred
method.

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 Symbols
Two symbols are used in this chart:

Transportation (either an arrow or a small
circle)

Action (e.g., grasp, position, use, release)
A sketch of the workplace is drawn,
indicating the contents of the bins and the
location of tools and materials.
Record the motions of one hand at a time
Usually necessary to redraw the chart

February 2, 2017 Lab # 6: Method Study 44

 Left-Hand-Right-Hand Chart (An
Example)

February 2, 2017 Lab # 6: Method Study 45

 L-R Hand Chart of Signing a
Letter
LEFT HAND RIGHT HAND
Reach for pen

Grasp pen

Carry pen to
paper

Sign letter
Hold Letter
Return pen to
holder
Release pen in
holder
Move hand back
to letter

February 2, 2017 Lab # 6: Method Study 46

 LEFT HAND RIGHT HAND
Reach for Reach for nut
bolt in bin 1 in bin 2
Grasp bolt Grasp nut
Carry bolt to Carry nut to
work area work area
Position bolt Position nut

Hold Bolt Assemble nut

Carry
assembly to Release nut
bin 3
Release
February 2, 2017 Lab # 6: Method Study 47
 Man-machine chart
The worker and machine process chart (Man-
machine chart) is used to study, analyze, and
improve one workstation at a time.
The chart shows the exact time relationship
between the working cycle of the person and
operating cycle of the machine.
These facts can lead to utilization of both worker
and machine time, and a better balance of the
work cycle.

February 2, 2017 Lab # 6: Method Study 48

 Worker-Machine Chart for a Gourmet
Coffee Store

February 2, 2017 Lab # 6: Method Study 49

 Worker-Machine Chart for a Gourmet
Coffee Store

The customer, the clerk, and the coffee grinder (machine) are
involved in this operation. It required 1 minute and 10 seconds for
the customer to purchase a pound of coffee in this particular store.
During this time the customer spent 22 seconds, or 31 percent of the
time, giving the clerk his order, receiving the ground coffee, and
paying the clerk for it. He was idle during the remaining 69 percent
of the time. The clerk worked 49 seconds, or 70 percent of the time,
and was idle 21 seconds, or 30 percent of the time. The coffee
grinder was in operation 21 seconds, or 30 percent of the time, and
February 2, 2017 Lab # 6: Method Study 50
 Multiple Activity
Charts
Also known as Gang Process Charts
Used when several workers operate a
single machine or render a single service
Used when a single worker is operating
several machines
Used to show the exact relationship
between idle and operating times of both
workers and machines
February 2, 2017 Lab # 6: Method Study 51
 Multiple Activity Charts
(Cont.)

An operation performed by one member of

the group may continue while another
member is performing more than one
operation.
The chart should cover the complete cycle
for the longest performing member.

February 2, 2017 Lab # 6: Method Study 52

 Activity Chart

Subject: Semi-Auto Machine Present

Time Operator Machine

1 Load machine Being loaded

2
3
Idle Run
4
5
6 Unload Being Unloaded

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 Activity Chart for Two-
Person

February 2, 2017 Lab # 6: Method Study 54

 Activity Chart of Emergency
Tracheotomy

February 2, 2017 Lab # 6: Method Study 55

 Any Question

February 2, 2017 Lab # 6: Method Study 56