3.i work study

3.i3.i An Introduction to An Introduction to

Industrial Engineering Industrial Engineering and and Work Study Work Study

3.i.A3.i.A Industrial Industrial EngineeringEngineering

Productivity improvement through :Productivity improvement through : Work StudyWork Study Method StudyMethod Study Work MeasurementWork Measurement Fixing Standard timeFixing Standard time Work SamplingWork Sampling O & MO & M

Plant Layout & Material HandlingPlant Layout & Material Handling Value Analysis & Value EngineeringValue Analysis & Value Engineering Quality ControlQuality Control Statistical Process ControlStatistical Process Control Problem Solving TechniquesProblem Solving Techniques

Source: Study material on Industrial Engineering-II, By Andhra Pradesh Productivity Council,

Chp. No.1 to 4, From Pg No. 1 to 32.

Work StudyWork Study

WORKSTUDY

METHOD STUDY

WORK MEASUREMENT

HIGHER PRODUCTIVITY

TO SIMPLIFY THE JOB AND

DEVELOP MORE ECONOMICAL

METHODS OF DOING IT

TO DETERMINE HOWLONG IT SHOULD TAKE

TO CARRY OUT

Continuous efforts are put up for improving the Utilization of Continuous efforts are put up for improving the Utilization of resources. This needs defining appropriate measures of resources. This needs defining appropriate measures of performance.performance.

The Ratio of output produced to the input resources utilized in the production

Input resources in any Productive System are :- Land- Material- Machines- Men

Productivity ConceptsProductivity Concepts

Total Productivity = Total Productivity = Aggregate OutputAggregate Output Aggregate inputAggregate input

Partial Productivity = Partial Productivity = Aggregate outputAggregate output Any single inputAny single input

Productivity Measurement = Productivity Measurement = National Level MACRONational Level MACRO Industry Level MACROIndustry Level MACRO

Express output and input in Monetary termsExpress output and input in Monetary terms

Labour Productivity = Output per workerLabour Productivity = Output per worker

Productivity ConceptsProductivity Concepts

More output with same or lesser input.More output with same or lesser input. Same output is produced with lesser input.Same output is produced with lesser input. More output with more input but proportional output More output with more input but proportional output

is more being more than the increase in input.is more being more than the increase in input. Financial Measure :Financial Measure :

Total output = cost of Product soldTotal output = cost of Product sold Total expenses (input) = cost of goods Total expenses (input) = cost of goods

producedproduced Productivity = sales / cost of salesProductivity = sales / cost of sales Profit = sales – Cost of SalesProfit = sales – Cost of Sales

Benefits of Higher Benefits of Higher ProductivityProductivity

Return on Investment ProfitReturn on Investment Profit

------------------------------- ------------------------------- == --------------------- ---------------------

A measure of Productivity Total InvestmentA measure of Productivity Total Investment

Productivity of materialsProductivity of materials Productivity of Land – Buildings Productivity of Land – Buildings Productivity of LabourProductivity of Labour

Benefits of Higher Benefits of Higher ProductivityProductivity

Time required to produce one unit of an output. (Man Time required to produce one unit of an output. (Man Hours)Hours)

Variation in standard – Actual inputs – (Machine Variation in standard – Actual inputs – (Machine Hours)Hours)

Contributing Factors :Contributing Factors : Design aspectsDesign aspects StandardizationStandardization Quality StandardsQuality Standards Productive MachinesProductive Machines Operating ConditionsOperating Conditions

Contd…Contd…

Factors Contributing To Factors Contributing To Productivity Productivity ImprovementImprovement

Interaction between men & machinesInteraction between men & machines Working methods of operativesWorking methods of operatives

Proper planning of the above will help improving productivity.Proper planning of the above will help improving productivity. Operational Inefficiencies arise out of Operational Inefficiencies arise out of

Improper planning of workImproper planning of work Improper maintenance of machinesImproper maintenance of machines Carelessness & negligence of workersCarelessness & negligence of workers

Factors important in raising productivityFactors important in raising productivity Mangerial efficiencyMangerial efficiency Operative efficiencyOperative efficiency

Factors Contributing To Factors Contributing To Productivity Productivity ImprovementImprovement

Role of Management in Role of Management in coordinating resources of coordinating resources of

an enterprisesan enterprises

Work Content and Ineffective TimeWork Content and Ineffective Time Reduce work contentReduce work content Reduce Ineffective TimeReduce Ineffective Time

1.1. Basic Work Content is the irreducible minimum Basic Work Content is the irreducible minimum time theoretically required to produce one unit of time theoretically required to produce one unit of outputoutput

2.2. Total work Content = Basic work content Total work Content = Basic work content

+ Excess Time+ Excess Time

Techniques For Techniques For Productivity Productivity ImprovementImprovement

3.3. Excess Time = Time due to defects in design Excess Time = Time due to defects in design or or Specifications of the productSpecifications of the product ++ Time due to inefficient methods Time due to inefficient methods of manufactureof manufacture

Ineffective time is the time for which the worker or the Ineffective time is the time for which the worker or the

machine or both are idle due to the short comings of the machine or both are idle due to the short comings of the

management or the workermanagement or the worker

Techniques For Techniques For Productivity Productivity ImprovementImprovement

TOTALWORK

CONTENT

TOTALINEFFECTIVE

TIME

TOTALTIMEOF

OPERATIONUNDER

EXISTINGCONDITIONS

Basic Work Content

Of Product and / or operation

Work Content AddedBy defects in product orSpecifications of product

Work Content AddedBy inefficient methods of Manufacture or operation

In efficient TimeDue to short coming Of the management

Ineffective Time

With in the controlOf the worker

Work Contents And Work Contents And Ineffective TimeIneffective Time

Work Content Due To Work Content Due To Product And Product And

ProcessProcess

BASICWORK

CONTENT

A.1. Bad Design Of ProductPrevent use of most economic process

A.2. Lack Of StandardizationPrevent use of high production processA.3. Incorrect Quality Standards Cause Unnecessary Work

B.1. Wrong Machine Used

B.2. Process Not Operated Correctly Or in bad conditions

B.3. Wrong Tools Used

B.4. Bad Layout Causing Wasted Movement

B.5. Operative’s Bad Working Methods

TOTALWORK

CONTENTOF THE

PRODUCT

TOTALWORK

CONTENT

INEFFECTIVETIME

WORK CONTENT ADDEDBy defects in design or specification of the products

WORK CONTENT ADDEDBy inefficient methods of Manufacture or operations

Ineffective Time Due To Ineffective Time Due To Shortcomings On The Part Of Shortcomings On The Part Of

Management And WorkersManagement And Workers

C.1. Excessive Product VarietyAdds idle time due to short runs

C.2. Lack Of StandardizationAdds idle time due to short runs

C.3. Design Changes

Add ineffective time due to stoppages and rework

C.4. Bad Planning of work and order adds idle time of men and machines

C.5. Lack of raw Materials due to bad planning adds idle time of men and machines

C.6. Plant Breakdowns add idle time of men and machines

C.7. Plant In Bad Condition adds ineffective time due to scrap and rework0

C.8. Bad Working Conditions Add ineffective time through forcing workers to rest

TIME OF OPERATIONWITHIN THE

CONTROL OF THE MANAGEMENT

TOTAL TIME OFOPERATION

UNDEREXISTING

CONDITIONS

WORK CONTENT

INEFFECTIVE TIMEDue to shortcomings of the management

BASIC

EXCESS

C.9. Accidents Add ineffective time through stoppages and absence

D.1. Absence, Lateness and Idleness Add ineffective time

D.2. Careless Workmanship Adds ineffective time due to scrap and rework

D.3. Accidents Adds ineffective time through stoppages and absence

INEFFECTIVE TIMEWith in the control of the worker

How Management Techniques How Management Techniques Can Reduce Can Reduce

Work ContentWork ContentBASICWORK

CONTENT

A.1. Product Development And Value Analysisreduce excess work content due to design defects

TOTALWORK

CONTENTTOTAL

TIME

A.2. Specialization And Standardizationenable high production process to be usedA.3. Market Consumer And Product Researchensure correct quality standards A.4. Product Development And Value Analysisreduce excess work content due to excess material

B.1. Process Planning ensure collection of correct machinesB.2. Process Planning And Researchensure correct operation of process B.3. Process Planning And Method Studyensure correct selection of tools B.4. Method Studyensure correct operation of process B.5. Method Study And Operator Trainingreduce work content due to bad working methods

BASICWORK

CONTENT=

ExcessWork content

totallyEliminated

if allTechniques

applied

E

L

I M

I

N

A

T

E

D

Ineffective Time

(to be eliminated)

How Management Techniques How Management Techniques Can ReduceWork Can ReduceWork

Content ContentBASICWORK

CONTENT

C.1. Marketing And Specializationreduce idle time due to product variety

TOTALTIME

IF ALLTECHNIQUESPERFECTLY

APPLIED

C.2. Standardization idle time due to short runsC.3. Product Developmentreduces ineffective time due to changes in design C.4.Production Control based on work measurement reduce idle time due to bad planningC.5.Material Control Reduces idle time due to lack of raw materialsC.6. Maintenance – reduces idle time of men and machines due to breakdowns

C.7. Maintenance – reduces ineffective time due to plant in bad condition

C.8. Improved Working Conditions

enables workers to work steadily

C.9. Safety measures reduce ineffective time due to accidents

BASICWORK

CONTENT

=

Ineffective TimeTotally Eliminatedif all TechniquesPerfectly applied

D.1. Sound Personal Policies and Incentivesreduce ineffective time due to absence, e.t.c D.2.Personal Policy And Operator Trainingreduce ineffective time due to carelessness D.3. Safety Trainingreduces ineffective time due to accidents

Excess work Content

Already elim

inated

Work Study = Time and Motion StudyWork Study = Time and Motion Study A scientific approach to study all forms of work with a view A scientific approach to study all forms of work with a view

to increase productivity.to increase productivity. Work Study is a generic term for those techniques, Work Study is a generic term for those techniques,

particularly method study and work measurement, which are particularly method study and work measurement, which are used in the examination of human work in all its contexts, used in the examination of human work in all its contexts, and which lead systematically to the investigation of all the and which lead systematically to the investigation of all the factors which affect the efficiency and economy of the factors which affect the efficiency and economy of the situation being reviewed, in order to effect improvement.situation being reviewed, in order to effect improvement.

Work study generally helps in improving productivity Work study generally helps in improving productivity without any major investmentwithout any major investment

3.i.B3.i.B Work Study Work Study

Work measurement is the application of techniques Work measurement is the application of techniques designed to establish the time for a qualified worker to designed to establish the time for a qualified worker to carry out a specified job at a defined level of performancecarry out a specified job at a defined level of performance

Work measurement is concerned with investigation and Work measurement is concerned with investigation and reduction of any ineffective time and subsequent reduction of any ineffective time and subsequent establishment of time standards for the operation when establishment of time standards for the operation when carried out in the improved fashion, only after method carried out in the improved fashion, only after method study has been conducted.study has been conducted.

3.i.B3.i.B Work Measurement Work Measurement

Method Study is the systematic Method Study is the systematic recording and critical examination of recording and critical examination of existing and proposed ways of doing existing and proposed ways of doing work, as a means of developing and work, as a means of developing and applying easier and more effective applying easier and more effective methods and reducing costs.methods and reducing costs.

Method Study is concerned in the Method Study is concerned in the reduction of work content.reduction of work content.

3.ii Method Study3.ii Method Study

SelectSelect : Select the job to be studied : Select the job to be studied

ExamineExamine : Examine the recorded facts critically and challenge : Examine the recorded facts critically and challenge everything that is done considering the purpose & place where everything that is done considering the purpose & place where it is performed, the sequence, the person doing and the means it is performed, the sequence, the person doing and the means by which it is doneby which it is done

DevelopDevelop – Develop the most economic method taking into – Develop the most economic method taking into account and circumstances.account and circumstances.

MeasureMeasure – Measure the quantity of work involved in the – Measure the quantity of work involved in the method selected and calculate the standard time for doing it.method selected and calculate the standard time for doing it.

3.ii.A3.ii.A Basic Procedure To Basic Procedure To Conduct Work StudyConduct Work Study

DefineDefine – Define the new method and the related time so that it – Define the new method and the related time so that it can always be identified.can always be identified.

InstallInstall – Install the new method as agreed standard practice – Install the new method as agreed standard practice with the time allowed.with the time allowed.

MaintainMaintain – Maintain the new Standard Practice by proper – Maintain the new Standard Practice by proper control procedure.control procedure.

Basic Procedure To Conduct Basic Procedure To Conduct Work Study…Work Study…

Good relations between Management and Good relations between Management and workersworkers

Good working conditions and environmentGood working conditions and environment

Workers to have confidence in the sincerity Workers to have confidence in the sincerity of Managementof Management

Good Human relations and working Good Human relations and working Conditions.Conditions.

Important Pre Requisites Important Pre Requisites In Conducting Work StudyIn Conducting Work Study

Direct Means of Raising Direct Means of Raising ProductivityProductivity

TYPE OF TYPE OF IMPROVE-IMPROVE-

MENTMENT

MEANMEANSS

COSCOSTT

HOW HOW QUICKLY QUICKLY CAN CAN RESULTS RESULTS BE BE ACHIEVEACHIEVEDD

EXTENT EXTENT OF OF IMPROVIMPROVEMENT EMENT IN IN PRODUCPRODUCTIVITYTIVITY

THE THE ROLE OF ROLE OF WORK WORK STUDYSTUDY

1.Development 1.Development of new basic of new basic process or process or fundamental fundamental improvement of improvement of existing onesexisting ones

Basic Basic researchresearch

Applied Applied researchresearch

Pilot Pilot plantplant

HighHigh Generally Generally YearsYears

No No Obvious Obvious LimitLimit

Method Method Study to Study to improve ease improve ease of operation of operation and and maintenance maintenance at design at design stagestage

2. Install 2. Install more modern more modern or higher – or higher – capacity plant capacity plant or equipment or equipment or modernise or modernise existing plantexisting plant

PurchasPurchase e Process Process ResearcResearchh

HighHigh Immeditly Immeditly

After After InstallationInstallation

No No Obvious Obvious LimitLimit

Method Method study in study in plant layout plant layout and to and to improve ease improve ease of operation of operation when when modernisingmodernising

CA

PIT

AL

I

NV

ES

TM

EN

T

APPRO

ACH

TYPE OF TYPE OF IMPROVEMENIMPROVEMEN

TTMEANSMEANS

COSTCOST HOW HOW QUICKLY QUICKLY CAN CAN RESULTS BE RESULTS BE ACHIEVEDACHIEVED

EXTENT OF EXTENT OF IMPROVEMENT IMPROVEMENT IN IN PRODUCTIVITYPRODUCTIVITY

THE ROLE THE ROLE OF WORK OF WORK STUDYSTUDY

3.Reduce the 3.Reduce the work content work content of the productof the product

Product Product researchresearch

Product Product developmentdevelopment

Quality Quality mgmt.mgmt.

Method Method StudyStudy

Value Value AnalysisAnalysis

Not high Not high compar-compar-ed with 1 ed with 1 and 2and 2

Generally Generally monthsmonths

Limited – of the Limited – of the same order as same order as that to be that to be expected from 4 expected from 4 & 5 . Should & 5 . Should precede action precede action under those under those heads. heads.


(and its (and its extension, extension, value value analysis) to analysis) to improve improve design for design for ease of ease of productionproduction

4.Reduce the 4.Reduce the work content work content of the processof the process

Process Process researchresearch

Pilot plantPilot plant

Process Process planningplanning


Operator Operator trainingtraining

Value Value AnalysisAnalysis

LowLow ImmediateImmediate Limited, but Limited, but often of a high often of a high orderorder

Method Method Study to Study to reduce reduce wasted wasted effort and effort and time in time in operating operating the process the process by by eliminating eliminating unnecessarunnecessary movementy movement

APPRO

ACH

B E

T T

E R

M

A N

A G

E M

E N

T


TYPE OF TYPE OF IMPROVEMEIMPROVEME

NTNTMEANSMEANS

COSTCOST HOW HOW QUICKLY QUICKLY CAN CAN RESULTS BE RESULTS BE ACHIEVEDACHIEVED

EXTENT OF EXTENT OF IMPROVEMENIMPROVEMENT IN T IN PRODUCTIVITPRODUCTIVITYY

THE ROLE OF THE ROLE OF WORK STUDYWORK STUDY

5. Reduce 5. Reduce ineffective ineffective time time (whether (whether due to due to management management or to or to workers)workers)

LOWLOW May start May start slowly but slowly but effect grows effect grows quicklyquickly

Limited, but Limited, but often of a often of a high orderhigh order

Work Work measurement to measurement to investigate investigate existing practice. existing practice. Locate ineffective Locate ineffective time and set time and set standards of standards of performance as a performance as a basis for – basis for –

A. Planning and A. Planning and ControlControl

B. Utilisation of B. Utilisation of plant.plant.

C. Labour cost C. Labour cost controlcontrol

D. Incentive D. Incentive schemesschemes

APPRO

ACH

B E

T T

E R

M

A N

A G

E M

E

N T


Evaluation of Human PerformanceEvaluation of Human Performance Involvement of workers – supervisor – work study - Involvement of workers – supervisor – work study -

man and management and their respective roles.man and management and their respective roles. Work study man to have experience, personal Work study man to have experience, personal

qualities, sincerity and honesty, enthusiasm, interest qualities, sincerity and honesty, enthusiasm, interest and sympathy with people, tact, good appearance and and sympathy with people, tact, good appearance and self confidence, ability to convince.self confidence, ability to convince.

Human Factors In The Application Human Factors In The Application Of Work StudyOf Work Study

3.i work study

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