Method StudyMethod Study

Method studyMethod study is the is the systematic recordingsystematic recording and and critical examinationcritical examination of ways of ways of doing things in order to make improvements. of doing things in order to make improvements.

The basic approach to method study consists of the following eight The basic approach to method study consists of the following eight steps:steps:

1.1. SELECTSELECT the work to be studied and define its boundaries. the work to be studied and define its boundaries.2.2. RECORDRECORD the relevant facts about the job by direct observation and the relevant facts about the job by direct observation and

collect such additional data as may be needed from appropriate collect such additional data as may be needed from appropriate sources.sources.

3.3. EXAMINEEXAMINE the way the job is being performed and challenge its the way the job is being performed and challenge its purposepurpose, , placeplace, , sequencesequence and and method of performancemethod of performance..

4.4. DEVELOPDEVELOP the most practical, economic and effective method. the most practical, economic and effective method. 5.5. EVALUATEEVALUATE different alternatives to developing a new improved different alternatives to developing a new improved

method, and compare the cost-effectiveness of the selected new method, and compare the cost-effectiveness of the selected new method with the current method of performance.method with the current method of performance.

6.6. DEFINEDEFINE the new method in a clear manner and present it to those the new method in a clear manner and present it to those concerned, management, supervisors and workers.concerned, management, supervisors and workers.

7.7. INSTALLINSTALL the new method as standard practice and train the the new method as standard practice and train the persons involved in applying it.persons involved in applying it.

8.8. MAINTAINMAINTAIN the new method & introduce control procedures to the new method & introduce control procedures to prevent a drawback to the previous method of work.prevent a drawback to the previous method of work.

Selecting the work to be studiedSelecting the work to be studiedThere are three factors that should be kept in There are three factors that should be kept in

mind when selecting a job.mind when selecting a job.1.1. Economic or cost-effective considerations.Economic or cost-effective considerations.2.2. Technical considerations.Technical considerations.3.3. Human considerations.Human considerations.

1.1. Economic considerationsEconomic considerations: : It is obviously a waste of time to start or continue It is obviously a waste of time to start or continue

a long investigation if the economic a long investigation if the economic importance of a job is small. importance of a job is small.

Questions that should always be asked Questions that should always be asked • Will it pay to begin a method study of this job? Or Will it pay to begin a method study of this job? Or

• Will it pay to continue this study?Will it pay to continue this study?

Obvious choices for study are:Obvious choices for study are:

A.A. KeyKey profit-generating or costly operationsprofit-generating or costly operations or ones with the largest or ones with the largest Scrap/waste rates.Scrap/waste rates.

B.B. BottlenecksBottlenecks which are holding up other production operations, or which are holding up other production operations, or lengthy operations that consume a great deal of time.lengthy operations that consume a great deal of time. C.C. Operations involving repetitiveOperations involving repetitive workwork using a great deal of labor using a great deal of labor

and ones that are likely to run for a long time.and ones that are likely to run for a long time. D.D. Movements of material over long distancesMovements of material over long distances between workstations, between workstations, those involving the use of a relatively large proportion of labor or those involving the use of a relatively large proportion of labor or which require repeated handling of material.which require repeated handling of material.

One of the easiest techniques that can be used to identify key One of the easiest techniques that can be used to identify key operations as listed in part operations as listed in part ((AA)) is the is the Pareto analysisPareto analysis (sometimes (sometimes also referred to as “the ABC analysis of value analysis”). also referred to as “the ABC analysis of value analysis”).

The same observation can be extended by saying that among all the The same observation can be extended by saying that among all the

operations in a given plant a small number account for the largest operations in a given plant a small number account for the largest share of share of costcost or of or of profitprofit, or the largest percentage of , or the largest percentage of wastewaste..

To illustrate the point we will consider the following example. To illustrate the point we will consider the following example.

Let us assume that a certain enterprise produces 20 different products. Let us assume that a certain enterprise produces 20 different products. Each of these products generates a certain profit.Each of these products generates a certain profit.

By listing the annual production and profit contribution one obtains the By listing the annual production and profit contribution one obtains the results shown in results shown in table 6table 6..

The next step consists of rearranging these items in descending order of The next step consists of rearranging these items in descending order of importance according to profit. The result would then appear like the one importance according to profit. The result would then appear like the one shown in shown in table 7table 7..

From From table 7table 7 it can be seen that three products only, listed as “ it can be seen that three products only, listed as “AA items items”, ”, account for 60 per cent of the profit. account for 60 per cent of the profit.

These are the most profitable and any improvement in methods of These are the most profitable and any improvement in methods of producing these particular products would reflect highly on profits. They producing these particular products would reflect highly on profits. They would be a priority for study. would be a priority for study.

Products listed under Products listed under ““BB”,”, which are seven in number, contribute 25 per which are seven in number, contribute 25 per cent of the profit. They could then assume a second importance, while cent of the profit. They could then assume a second importance, while products products ““CC”” would command the last priority since their contribution to would command the last priority since their contribution to profit is minimal. profit is minimal.

The same type of analysis can be conducted to determine “the most The same type of analysis can be conducted to determine “the most costly products or processes” or “the products or processes that yield the costly products or processes” or “the products or processes that yield the highest waste”. highest waste”.

Those would then become a priority for study by the work study Those would then become a priority for study by the work study specialist.specialist.

2.2. Technical or technological considerationsTechnical or technological considerations: :

One of the important considerations is the desire by management to One of the important considerations is the desire by management to acquire more advanced technology, i.e. in equipment or in processes. acquire more advanced technology, i.e. in equipment or in processes.

Therefore, management may want to computerize its office paperwork Therefore, management may want to computerize its office paperwork or its inventory system, or to introduce automation in the production or its inventory system, or to introduce automation in the production operations. operations.

Before such steps are taken, a method study can point out the most Before such steps are taken, a method study can point out the most important needs of the enterprise in this respect. important needs of the enterprise in this respect.

The introduction of new technology should therefore constitute an The introduction of new technology should therefore constitute an important factor in the choice of methods of work to be investigated.important factor in the choice of methods of work to be investigated.

3.3. Human considerationsHuman considerations: :

Certain operations are often a cause of dissatisfaction by workers. Certain operations are often a cause of dissatisfaction by workers. They may bring on fatigue or monotony or may be unsafe to operate. They may bring on fatigue or monotony or may be unsafe to operate. The level of satisfaction should point to a need for method study. In a The level of satisfaction should point to a need for method study. In a

similar fashion, a choice of a particular job for study may lead to anxiety similar fashion, a choice of a particular job for study may lead to anxiety or ill feeling. The suggestion given here is to leave it alone.or ill feeling. The suggestion given here is to leave it alone.

Record the factsRecord the facts

The next step in the basic procedure, after selecting the The next step in the basic procedure, after selecting the work to be studied, is to record all the facts relating to work to be studied, is to record all the facts relating to the existing method. the existing method.

The success of the whole procedure depends on the The success of the whole procedure depends on the accuracy with which the facts are recorded, because accuracy with which the facts are recorded, because they will provide the basis of both the critical examination they will provide the basis of both the critical examination and the development of the improved method. and the development of the improved method.

Recording serves essentially as a basis for following Recording serves essentially as a basis for following analysis and examination. analysis and examination.

Recording may be carried out in two phases: Recording may be carried out in two phases:

FirstFirst, a rough sketch or charting of the job being studied to , a rough sketch or charting of the job being studied to establish whether the recorded information is of use; establish whether the recorded information is of use;

SecondSecond, a more formal and accurate chart or diagram to include , a more formal and accurate chart or diagram to include in a report or presentation.in a report or presentation.

Examine critically: byExamine critically: by using the questioning technique. using the questioning technique.

The questioning techniqueThe questioning technique is the means by which the critical is the means by which the critical examination is conducted, each activity being subjected in examination is conducted, each activity being subjected in turn to a systematic and progressive series of questions.turn to a systematic and progressive series of questions.

The primary questionsThe primary questions The questioning sequence used follows a well-established The questioning sequence used follows a well-established

pattern which examines:pattern which examines:

In the first stage of the questioning technique, the In the first stage of the questioning technique, the purpose, place, sequence, person and means of every purpose, place, sequence, person and means of every activity recorded are systematically questioned, and a activity recorded are systematically questioned, and a reason for each reply is required.reason for each reply is required.

The secondary questionsThe secondary questions

The The secondary questionssecondary questions cover the second stage of the cover the second stage of the questioning technique, during which the answers to the questioning technique, during which the answers to the primary questions are subjected to further question to primary questions are subjected to further question to determine whether possible alternatives of place, determine whether possible alternatives of place, sequence, persons and/or means are feasible and sequence, persons and/or means are feasible and preferable as a means of improvement upon the existing preferable as a means of improvement upon the existing methodmethod

Therefore, during this second stage of questioning Therefore, during this second stage of questioning (having asked already, about every activity recorded, (having asked already, about every activity recorded, what is done and why is it done), the method study what is done and why is it done), the method study person goes on to inquire: person goes on to inquire:

What What elseelse might be done? And, hence: What might be done? And, hence: What shouldshould be be done? In the same way, the answers already obtained done? In the same way, the answers already obtained on place, sequence, person and means are subjected to on place, sequence, person and means are subjected to further inquiry.further inquiry.

Combining the two Combining the two primary primary questions with the two questions with the two secondarysecondary questions questions under each of the headings “under each of the headings “purpose, placepurpose, place”, etc., yields the following ”, etc., yields the following list, which sets out the questioning technique in full:list, which sets out the questioning technique in full:

PURPOSEPURPOSE: What is done? Why is it done? What else might be done? : What is done? Why is it done? What else might be done? What should be done? What should be done?

PLACEPLACE: Where is it done? Why is it done there? Where else might it be done? : Where is it done? Why is it done there? Where else might it be done? Where should it be done? Where should it be done?

SEQUENCESEQUENCE: When is it done? Why is it done then? When might it be done? : When is it done? Why is it done then? When might it be done? When should it be done? When should it be done?

PERSONPERSON: Who does it? Why does that person do it? Who else might do it? : Who does it? Why does that person do it? Who else might do it? Who should do it? Who should do it?

MEANSMEANS: How is it done? Why is it done that way? How else might it be done? : How is it done? Why is it done that way? How else might it be done? How should it be done?How should it be done?

These questions, in the above sequence, must be asked systematically These questions, in the above sequence, must be asked systematically every time a method study is undertaken. every time a method study is undertaken.

They are the basis of successful method study.They are the basis of successful method study.