Productivity

Contents

Work Study Work Measurement Performance Rating Allowances Standard Time Synthetic Time Standards Work Sampling

Work Study

This method was developed to improve performance of a given work. It is the body of knowledge concerned with analysis of the work methods, and the standard proposed work methods. It is understood as systematic, objective and critical examination of the factors, affecting productivity for the purpose of improvement.

Objectives of Work Study

To analyze the present method of doing job, systematically in order to develop a new and better method. To increase the productivity by ensuring optimal use of available resources to achieve best quality with minimum cost. To improve operational efficiency. To establish standard time.

Benefit of Work Study

Increased Productivity, Reduced manufacturing cost, Improved work flow, Reduced material handling cost. Better manpower planning, Better working condition to employees, Better job satisfaction and well placed performance management system

Work Measurement

Measuring the work content of any activity under study

Method study and work measurement are the two techniques of work study. Motion study and Method Analysis is a tool for standardizing the methods of doing a job. Work measurement establishes the work content of a job.

Definition & Objectives

It is a application techniques designed to establish the work content of a specified task by determining the time required for carrying out the task at defined standard performance by a qualified worker. Work measurement helps in achieving Improved planning & Control of activities - More efficient manning of the plant - Reliable indices for labour performance - Reliable basis for labour cost control - Basis for sound incentives schemes

Benefits of work measurement

To develop a basis for comparing alternate methods. To prepare realistic work schedules. To set standards of performance for labour utilization. To compare actual time taken by the worker with allowed time. To assist in labour cost estimation. To provide information related to estimation of tenders, fixation of selling price and assessment of delivery schedule.

Method Study

It is a scientific technique of observing, recording, and critically examining the present method of performing task or job or operation with aim of improving the present method and developing new and cheaper method. It is also called as methods improvement or work improvement

Motion Study

It is the science of eliminating wastefulness resulting from using unnecessary, ill-directed and inefficient motion. The aim of motion study is to find and accomplish system of least waste methods of labour

Techniques of Work Measurement

Direct Time Study Synthesis Method Analytical Estimating Pre determined motion time system (PMTS) Work sampling or Activity Sampling

Steps in work measurement

Observed Time (breaking job into elements) Apply rating factor Normal Time Work content

Add Relaxation Allowances

Add contingency And other allowance if Required

Standard Time

Time Study - Definition

Time study is a work measurement technique for recording the times and rates of working for the elements of a specified job carried out under specified conditions and for analyzing the data so as to obtain the time necessary for carrying out the job at a defined level of performance. - ILO

The main objective of time study is to establish the standard time by direct observation. (This is the time within which an average worker working at normal pace should complete the task using a specified method.)

Some more objectives

To provide a basis of comparison for determining operating effectiveness. To determine standard cost. To set labour standard for satisfactory performance. To provide basis for setting incentive wages. To set completion schedule for individual operations or job. To determine the cycle time for completion of a job.

Performance Rating or Rating/levelling factor

1. 2. 3.

It is determine by comparing actual pace or speed of working (of worker studied) with the standard pace or speed of working (of the qualified worker) Rating Factor = Rating of Observed worker ______________________ Rating of qualified worker Rating Scale 60 - 80 Scale 75 -100 Scale 100 -133 1/3 Scale

Rating scales comparison

Rating Assigned
60-80 75-100 100-133 1/3

Level of Performance No Activity

Corresponding Walking Speed

Nil

40
60

50
75

67
100

Very Slow, No interest to do job

Normal, Steady

2 mph
3 mph

80
100

100
125

133 1/3
167

Performance of qualified worker

Very fast, Incentive motivated

4 mph
5 mph

Relevant Allowances Generally taken as a % of basic or normal time

Normal or Basic Time = Observed Time x Rating factor = Observed Time x Observed rating ______________ Standard rating

Types

Relaxation Allowances (RA/PFD) It is given to the work to overcome the fatigue due to physical exertion, posture, concentration, working condition and personal needs. These allowance varies from 10 to 20% of normal time. Contingency Allowances (CA) It is given for infrequent or non repetitive activities such as obtaining material from stores, sharpening tools, getting special tool from the store and consultation with the supervisor. It is usually 5% of normal time

Contd

1.

2.

Process Allowances Allowances given to the worker to compensate himself/herself for enforced idleness due to nature of process or operation. e.g. working on automatic machine. Special Allowances Interference Allowance It is given to a worker when he/she is looking after 2 or 3 machines. Periodic Activity Allowance This for the activities which are carried out periodically during a work cycle e.g. setting up tool on the machine.

Standard Time

Standard Time can be calculated as follows Standard Time = Normal Time + All Relevant Allowances

Example 1
For some work, the basic time is established to be 20 sec. If for three observations, a time study observer records ratings of 100, 125 and 80 respectively, on a 100-normal scale what are the observed timings? Solution: Observed Time x Observed Rating = Normal/Basic Time x Standard Rating

Contd
Given Normal/Basic Time is 20 Seconds Standard Time is 100 For Observation 1 Observe Rating is 100 Observed Time = 20 x 100/100 = 20 sec. For Observation 2 Observe Rating is 125 Observe Time = 20 x 100/125 = 16 sec. For Observation 3 Observe Rating is 80 Observe Time = 20 x 100/80 = 25 sec.

Example 2
Calculate standard time per unit for following data: Observed time per unit is 5 min. and rating factor is 120%, Total Allowance = 331/3% of normal time. Solution: Normal Time per unit = Observed time per unit x Rating factor = 5 x 120/100 = 6 min. Allowance = 331/3 % of normal time = 33.33 x 6/100 = 2 min Standard Time per unit = Normal Time per unit + Allowance = 6 + 2 = 8 min per unit

Synthesis Method

It is a technique of work measurement for building up the time required to do a job at a defined level of performance. It is done by synthesizing or totaling elemental time value obtained form previous time studies on other jobs containing similar job element or from standard data or synthetic data or built up time standards.

Standard Data

It is a catalogue of normal/basic time values for different elements of jobs. This is prepared by compiling the timings of a number of standard elements. Once the standard data catalogue is built up, it is require to list the job elements of an operation, refer to the standard data catalogue and obtain the elemental time values from standard data catalogue and add them up (i.e. synthesize). Hence total time is obtained gives an estimate of normal time for a job which can converted into standard time by adding relevant allowances.

Advantages

Reliable as built up time values of standard data catalogue based on large no. of time studies. Can be used for estimating labour times for preparing cost estimates for new job for which the selling price has to be quoted to customer. More economical and comparatively less time consuming.

Applications

To estimate standard time for new job. Used for basis for designing incentive scheme for the worker. To estimate production time for determining the prices of products to be sold.

Work Sampling

It is a work measurement technique that randomly sample the work of one or more employees at periodic intervals to determine the proportion of total operations that is accounted for in one particular activity. This is used to estimate the percentage of time spent by the employees in unavoidable delays, repairing finished products from an operation, and supplying material to an operation.

Work Sampling Procedure

This technique is based on the statistical premise that the occurrences in an adequate random sampling observations of an activity will follow the same distribution pattern that might be found in a lengthy, continuously study of the same activity. Formula: p = x/N = No. of observations of the activity ____________________________ Total no. of observations

Advantages

Can be used to measure many activities that are impractical to measure by time study. Not necessary to use a trained person for making the observations. Measures the utilization of people and equipment directly. Provides observation over a sufficiently long period of time there by reducing the chance of variation affecting the results. Economical compared to continuous time study. Work sampling measurements can be made with preassigned degree of reliability.

Limitations

Difficulty in understanding of statistical work sampling by worker. If random sampling is not done, then the result may not be accurate. Comparatively less helpful in improving work methods than time study methods.