Outline

1.
1.Work
WorkStudy
Study
2.
2. Method
Method Study
Study
3.
3.Various
Various Charts
Charts

October 15, 2016

Lab # 6: Method Study

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).

October 15, 2016

Lab # 6: Method Study

Work Study

October 15, 2016

Lab # 6: Method Study

(Cont.)

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
Analyst:

Flow Diagrams & Process Charts etc.

Critical questioning techniques.
October 15, 2016

Lab # 6: Method Study

Method

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

October 15, 2016

Lab # 6: Method Study

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
unnecessary fatigue.

effort

and

reduction

of

Development of better working environment.

October 15, 2016

Lab # 6: Method Study

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.
October 15, 2016

Lab # 6: Method Study

Methodology (Cont.)
Select
Recor
d
Exami
ne
OK
?

October 15, 2016

Develo
p
Install
Maintai
Lab # 6: Method
n Study

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

October 15, 2016

Lab # 6: Method Study

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)

October 15, 2016

Lab # 6: Method Study

10

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.
October 15, 2016

Lab # 6: Method Study

11

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.
October 15, 2016

Lab # 6: Method Study

12

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.
October 15, 2016

Lab # 6: Method Study

13

Assembly Chart

(Cont.)

Assembly Chart for prod

ucing Cheese Hamburger

October 15, 2016

Lab # 6: Method Study

14

Assembly Chart

October 15, 2016

Lab # 6: Method Study

(Cont.)

15

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.
October 15, 2016

Lab # 6: Method Study

16

Operation Process
Chart (Cont.)
Operations charts show the introduction of
raw materials at the top of the chart on a
horizontal line.
Operation
Number

Pieces / Hr
Hours / 1000

Some parts require no fabrication steps.

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

October 15, 2016

Lab # 6: Method Study

17

Operations Chart
Steps
Step
by
Step
Procedures
Preparing an Operations Chart:

For

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
October 15, 2016

Lab # 6: Method Study

18

Operation Process
Chart

Operation Process Chart f

or Refrigerator Support

October 15, 2016

Lab # 6: Method Study

19

Operation Process
Chart

October 15, 2016

Lab # 6: Method Study

20

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.
October 15, 2016

Lab # 6: Method Study

21

Flow Diagram

(Cont.)

Buyer

75 ft.
You

October 15, 2016

Lab # 6: Method Study

22

Flow Diagram

October 15, 2016

Lab # 6: Method Study

(Cont.)

23

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.
October 15, 2016

Lab # 6: Method Study

24

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

October 15, 2016

Lab # 6: Method Study

25

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
October 15, 2016

Lab # 6: Method Study

26

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.

October 15, 2016

Lab # 6: Method Study

27

 Flow Process Types:

Product or Material type
Worker (Man) type
Machine type

October 15, 2016

Lab # 6: Method Study

28

ASME Standard
Symbols

October 15, 2016

Lab # 6: Method Study

29

Flow Process Chart

Symbols
Operation

Delay

Transportation

Storage

Inspection

October 15, 2016

Lab # 6: Method Study

30

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.
October 15, 2016

Lab # 6: Method Study

31

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

October 15, 2016

Lab # 6: Method Study

32

Inspection
Occurs when an object is examined for
identification

or

is

compared

with

standard as to quantify or quality

Examine the quantity or quality, read
steam

gauge

on

boiler,

detect

the

defectives

October 15, 2016

Lab # 6: Method Study

33

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
October 15, 2016

Lab # 6: Method Study

34

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

October 15, 2016

Lab # 6: Method Study

35

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

Operation and Inspection

October 15, 2016

Lab # 6: Method Study

36

Flow Process Chart-An

Example

Flow Process Chart Exam

ple

October 15, 2016

Lab # 6: Method Study

37

Flow Process Chart-An

Example
Process:
Subject:
Beginning:
Ending:

Emergency room admission

Ankle injury patient
Enter emergency room
Leave hospital
Insert Step
Append Step
Remove Step

Step
no.

Time
(min)

1
2
3
4
5

0.50
10.0
0.75
3.00
0.75

15
40
40

6
7
8
9
10

1.00
1.00
4.00
5.00
2.00

60
200

11
12
13
14
15

3.00
2.00
3.00
2.00
1.00
4.00
2.00
4.00
1.00

200
60
180
20

16
17
18
19

October 15, 2016

Summary
Activity
Operation
Transport
Inspect
Delay
Store

Distance

Number
of steps

Time
(min)

Distance
(ft)

5
9
2
3

23
11
8
8

815

Step description

(ft)
X

Enter emergency room, approach patient window

Sit down and fill out patient history
Nurse escorts patient to ER triage room
Nurse inspects injury
Return to waiting room

X
X
X
X
X
X

Wait for available bed

Go to ER bed
Wait for doctor
Doctor inspects injury and questions patient
Nurse takes patient to radiology

Technician x-rays patient

Return to bed in ER
Wait for doctor to return
Doctor provides diagnosis and advice
Return to emergency entrance area

X
X
X
X
X
X
X
X
X
X
X

Check out
Walk to pharmacy
Pick up prescription
Leave the building

Lab # 6: Method Study

38

Material Type Example

October 15, 2016

Lab # 6: Method Study

39

Man Type - Example

October 15, 2016

Lab # 6: Method Study

40

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.

October 15, 2016

Lab # 6: Method Study

41

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.

October 15, 2016

Lab # 6: Method Study

42

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

October 15, 2016

Lab # 6: Method Study

43

Left-Hand-Right-Hand Chart (An

Example)

October 15, 2016

Lab # 6: Method Study

44

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
October 15, 2016

Lab # 6: Method Study

45

LEFT HAND

RIGHT HAND

Reach for
bolt in bin 1
Grasp bolt
Carry bolt to
work area
Position bolt

Reach for nut

in bin 2
Grasp nut
Carry nut to
work area
Position nut

Hold Bolt
Carry
assembly to
bin 3
Release
October
15, 2016

Assemble nut
Release nut
Lab # 6: Method Study

46

Man-machine chart
The worker and machine process chart (Manmachine 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.
October 15, 2016

Lab # 6: Method Study

47

Worker-Machine Chart for a Gourmet

Coffee Store

October 15, 2016

Lab # 6: Method Study

48

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
October 15, 2016

Lab # 6: Method Study

49

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

October 15, 2016

Lab # 6: Method Study

50

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.

October 15, 2016

Lab # 6: Method Study

51

Activity Chart
Subject: Semi-Auto Machine
Time
1
2
3
4
5
6

October 15, 2016

Present

Operator

Machine

Load machine

Being loaded

Run

Idle
Unload

Being Unloaded

Lab # 6: Method Study

52

Activity Chart for TwoPerson

October 15, 2016

Lab # 6: Method Study

53

Activity Chart of Emergency

Tracheotomy

October 15, 2016

Lab # 6: Method Study

54

Any Question

October 15, 2016

Lab # 6: Method Study

55