Method StudyMethod Study

Man, Machines, Materials, Money, Technology and Man, Machines, Materials, Money, Technology and Time are the main resources required to produce goods Time are the main resources required to produce goods and are to be deployed in the most effective mannerand are to be deployed in the most effective manner

We have to select the best available combination of We have to select the best available combination of these resources at any point of time.these resources at any point of time.

Method Study helps in analysing the existing Method Study helps in analysing the existing methods and develop a more efficient method for methods and develop a more efficient method for

future.future.

3.ii Method Study

Method Study is the systematic recording and Method Study is the systematic recording and critical examination of existing and proposed critical examination of existing and proposed ways of doing work, as a means of developing ways of doing work, as a means of developing

and applying easier and more effective and applying easier and more effective methods and reducing costs.methods and reducing costs.

The objectives of Method Study are :The objectives of Method Study are :– Improvement of processes and proceduresImprovement of processes and procedures– Improvement in the design of plant and Improvement in the design of plant and

equipmentequipment– Improvement of plant layout.Improvement of plant layout.– Improvement in the use of men, materials and Improvement in the use of men, materials and

machines.machines.– Efficient materials handlingEfficient materials handling

3.2.A Definition And Objective of Method Study

– Improvement in the flow of production and Improvement in the flow of production and process.process.

– Economy in human effort and the reduction Economy in human effort and the reduction of unnecessary fatigue.of unnecessary fatigue.

– Method StandardizationMethod Standardization– Improvement in safety standards.Improvement in safety standards.– Development of a better physical working Development of a better physical working

environmentenvironment

Definition And Objective of Method Study

The solution of any problem follows the The solution of any problem follows the following sequence of phases in that orderfollowing sequence of phases in that order : :

1)1) Define: Define: The problem.The problem.2)2) Record: Record: All the facts relevant to the problem.All the facts relevant to the problem.3)3) Examine: Examine: The facts critically but impartially.The facts critically but impartially.4)4) Consider: Consider: The courses of actions (possible The courses of actions (possible

solutions) and decide which to follow.solutions) and decide which to follow.5)5) Implement:Implement: The solution.The solution.6)6) Follow Up:Follow Up: The development.The development.

The basic procedure for the whole of work The basic procedure for the whole of work study, which embraces the procedures of both study, which embraces the procedures of both method study and work measurement.method study and work measurement. Contd… Contd…

Procedure

Steps and Procedure to conduct Method Steps and Procedure to conduct Method Study :Study :

a)a) Select: Select: the work to be studied.the work to be studied.b)b) RecordRecord: : all the relevant facts about the all the relevant facts about the

present method by direct observation.present method by direct observation.c)c) ExamineExamine: : those facts critically and in an those facts critically and in an

orderly sequence, using the techniques orderly sequence, using the techniques best suited to the purpose.best suited to the purpose.

d)d) DevelopDevelop: : the most practical, economic and the most practical, economic and effective method, having due regard to all effective method, having due regard to all contingent circumstances.contingent circumstances.

Procedure…

a)a) Define: Define: the new method so that it can the new method so that it can always be identified.always be identified.

a)a) Install: Install: that methods as standard practice.that methods as standard practice.

a)a) Maintain: Maintain: that standard practice by regular that standard practice by regular routine checks.routine checks.

These are the seven essential stages in the These are the seven essential stages in the application of method study ; none can be application of method study ; none can be

excluded. Strict adherence to the sequence, as excluded. Strict adherence to the sequence, as well as to their content, is essential for the well as to their content, is essential for the

success of an investigation. They are shown success of an investigation. They are shown diagrammatically on the chart.diagrammatically on the chart.

Procedure…

Method StudyRecord

At Work Place By means of

At Work Place

By means of

Examine the facts critically

Two handed ; Simo ; Multiple Activity

Charts

Other MeansCycle Graphs ; Chronocycle Graphs ;Film Analysis ; Memotion Photography

Select

Define Scope of Study

Work which can be studiedWith economic advantage

Charts

Other Means

Outline Process ;Flow Process – Man type , Material type ;Multiple Activity ; TravelFlow Diagrams ; String Diagrams ; Models

Challenge

PURPOSE – PLACE – SEQUENCE – PERSON - MEANS

Seek Alternatives

Find PointersCombine or

ChangeSimplifyEliminat

eDevelopA record of an improved

methodRe - Examinethat record to

establish

Method Study to improve

methods of production

The Best Method under Prevailing Circumstances

Planning and ControlMaterials HandlingGeneral Environment and Working ConditionsPlant Layout

Mechanical Aids ; Manual Controls and Visual instrumentsEquipment design ; Jigs and fixturesLocal Working Conditions

Define

InstallThe Improved method

Plan - Arrange - Implement

MaintainVerify at regular intervals that

The important method as defined is in fact in use

To achieve improved factory and work space

layoutImproved design of equipment

Better working conditionsReduction of fatigue

Resulting in improved use of materialPlant and equipment

manpower

HigherProductivity

The Field Of Choice

Types of Jobs Examples Recording Technique

Complete Sequence of manufacture

Manufacture of an electric motor from raw material to dispatchTransformation of thread into cloth from preparation to inspectionReceipt, packing and dispatch of fruit

Outline process chartFlow process chartFlow diagram

Factory layout : movement of materials

Movements of a diesel engine cylinder head through all machining operations. Movements of grain between milling operations

Outline process chartFlow process chart–material typeFlow diagramTravel chartModels

The Field Of Choice…

Types of Jobs Examples Recording Technique

Factory layout : movement of workers

Labourers servicing spinning machine with bobbinsCooks preparing meals in a restaurant kitchen

Flow process chart-man type string diagramString diagram

Handling of materials

Putting materials into and taking them out of storesLoading lorries with finished products.

Flow process chart – material typeFlow diagramString diagram

Workplace layout

Light assembly work on a benchTypesetting by hand

Flow process chart-man type. Two-handed process chart. Multiple activity chart. Simo chart. Cyclegraph.Chronocyclegraph.

Types of Jobs Examples Recording Technique

Gang work or automatic machine operation

Assembly line Operator looking after semi-automatic lathe

Multiple activity chartFlow process chart-equipment type

Movements of operatives at work

Female operatives on short – cycle repetition workOperations demanding great manual dexterity

Multiple activity chartFlow process chart – equipment typeFilmsFilm analysisSimo chartMemotion photographyMicromotion analysis

The Field Of Choice…

When selecting a job for method study it will be found helpful to have a standerdised list of points to be covered as shown below :-

1.1. Product and operationProduct and operation2.2. Person who proposes investigationPerson who proposes investigation3.3. Reason for proposalReason for proposal4.4. Suggested limits of investigationSuggested limits of investigation5.5. Particulars of the jobParticulars of the job

a)a) How much is produced or handled How much is produced or handled per week?per week?

The Field Of Choice…

The most commonly used method study charts The most commonly used method study charts and diagrams and diagrams

A. Charts

Indicating process SEQUENCEOutline Process ChartFlow Process Chart – Man TypeFlow Process Chart – Material TypeFlow Process Chart – Equipment TypeTwo – Handed Process Chart

B. ChartsUsing a TIME SCALEMultiple Activity ChartSimo Chart

C. Diagrams

Indicating movementFlow DiagramString DiagramCyclegraphChromocyclegraphTravel Chart

Record, Examine, Develop…

Process Chart Symbols…

Indicates the main steps in a process, method or procedure.Indicates the main steps in a process, method or procedure.Usually the part, material or product concerned is modified or Usually the part, material or product concerned is modified or

changed during the operation. changed during the operation.

Inspection

Indicates an inspection for quality and / or check for quantityIndicates an inspection for quality and / or check for quantity

Operation

Transport

Indicates the movement of workers, materials or equipment from place Indicates the movement of workers, materials or equipment from place to placeto place

Temporary Storage or Delay

Indicates a delay in the sequence of events : for example, Indicates a delay in the sequence of events : for example, work waiting work waiting between consecutive operations, or any object laid between consecutive operations, or any object laid aside temporarily without aside temporarily without record until required. record until required.

Permanent Storage

Indicates a controlled storage in which material is received Indicates a controlled storage in which material is received into or issued into or issued from a store under some form of authorization; or from a store under some form of authorization; or an item is retained for an item is retained for reference purposes.reference purposes.

Combined Activities

Indicates a controlled storage in which material is received Indicates a controlled storage in which material is received into or issued into or issued from a store under some form of authorization; or from a store under some form of authorization; or an item is retained for an item is retained for reference purposes.reference purposes.

Process Chart Symbols…

The Outline Process ChartThe Outline Process Chart

ExampleExample

Assembling a switch rotorAssembling a switch rotor

Switch Rotor AssemblySwitch Rotor Assembly

The operations and inspections carried out on the The operations and inspections carried out on the spindle made from 10mm spindle made from 10mm ØØ steel rod are as follows steel rod are as follows

O 1O 1 Face, turn, undercut and part off on capstan latheFace, turn, undercut and part off on capstan lathe(0.025 (0.025 hrs)hrs)

O 2O 2 Face opposite end on the same machine(0.010 hrs). Face opposite end on the same machine(0.010 hrs). Transport to inspn deptTransport to inspn dept

I 1I 1 Inspect for dimensions and finish (no time fixed). Inspect for dimensions and finish (no time fixed). Transport to milling sectionTransport to milling section

O 3 O 3 mill four flats on end on a horizontal miller mill four flats on end on a horizontal miller (0.020 (0.020 hrs). Transport to work hrs). Transport to work benchbench

O 4 O 4 Remove burrs at the burring bench(0.020 hrs). Remove burrs at the burring bench(0.020 hrs). Transport to inspn deptTransport to inspn dept

I 2 I 2 Final inspn of machine (no time)Final inspn of machine (no time)

O5 O5 Degreasing(0.0015 hrs)Degreasing(0.0015 hrs)O6 O6 Cadmium plating(.008 hrs)Cadmium plating(.008 hrs)I3 I3 Final check (no time)Final check (no time)O7 O7 Face on both sides, bore the cored hole and ream Face on both sides, bore the cored hole and ream to to

size on a capstan lathe(0.080 hrs)size on a capstan lathe(0.080 hrs)O8 O8 Drill cross-hole and burr on two-spindle drill Drill cross-hole and burr on two-spindle drill

press(0.022 hrs)press(0.022 hrs)I4 I4 Final check dimensions and finish (no time)Final check dimensions and finish (no time)

Transport to finished parts stores and await with-Transport to finished parts stores and await with-drawl drawl for assembly.for assembly.

Note the numbering of operations and inspectionsNote the numbering of operations and inspections

Outline process chartOutline process chart

3.ii.D3.ii.D FLOW PROCESS CHARTFLOW PROCESS CHART

Process activity symbolsProcess activity symbols

– OperationOperation

– InspectionInspection

– TransportTransport

– Temporary storage or DelayTemporary storage or Delay

– Permanent storagePermanent storage

3.ii.D Flow process chart3.ii.D Flow process chart 2/62/6

A FLOW PROCESS CHART records what the A FLOW PROCESS CHART records what the worker does.worker does.

It is a chart setting out the frequency of flow of It is a chart setting out the frequency of flow of a product or procedure by recording all events a product or procedure by recording all events under review using process chart symbols.under review using process chart symbols.

there are different types of flow process charts.there are different types of flow process charts.

PurposePurpose::

To set out the sequence of the flow of a product To set out the sequence of the flow of a product or a procedure by recording all the events under or a procedure by recording all the events under review review

( Inspection ) using the appropriate process chart ( Inspection ) using the appropriate process chart symbols.symbols.

Activities recorded in the flow chartActivities recorded in the flow chart

Those where some thing is happening to Those where some thing is happening to the work piece.the work piece.

Those where the work piece is not Those where the work piece is not touched – (stored or standstill)touched – (stored or standstill)

Three types of flow process chartsThree types of flow process charts

Man typeMan type– Flow chart which records what the worker doesFlow chart which records what the worker does

Material typeMaterial type– Flow chart which records how material is handled or Flow chart which records how material is handled or

treatedtreated

Equipment typeEquipment type– Flow chart which records how the equipment is Flow chart which records how the equipment is

usedused

FLOW PROCESS CHART FOR FLOW PROCESS CHART FOR ENGINE ENGINE

Stripping – Cleaning - GreasingStripping – Cleaning - Greasing

Critical ExaminationCritical Examination

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

OPERATIONSOPERATIONS

Make ReadyMake Ready

DoDo

Put AwayPut Away

Make ready and put away operations can Make ready and put away operations can be represented by transport and be represented by transport and inspection symbols inspection symbols

DO operations can be shown by “O”DO operations can be shown by “O”

CRITICAL EXAMINATIONCRITICAL EXAMINATION- - Primary questionsPrimary questions

The Purpose The Purpose for which…for which…

The Place The Place at which…at which…

The sequence The sequence in which…in which…

The person The person by which…by which…

The means The means by which…by which…

……the activities are undertakenthe activities are undertaken

CRITICAL EXAMINATIONCRITICAL EXAMINATION- - Primary questionsPrimary questions

With a view toWith a view to

EliminatingEliminatingCombiningCombiningRearrangingRearrangingSimplifyingSimplifying

……those Activitiesthose Activities

PRIMARY QUESTIONSPRIMARY QUESTIONS

PURPOSEPURPOSE ELIMINATEELIMINATE

PLACEPLACE COMBINECOMBINE

SEQUENCESEQUENCE REARRANGEREARRANGE

PERSON PERSON REARRANGEREARRANGE

MEANSMEANS SIMPLIFYSIMPLIFY

EXAMPLE: ENGINE EXAMPLE: ENGINE Stripping – Cleaning - DegreasingStripping – Cleaning - Degreasing

1.1. String diagramString diagram

2.2. Flow Process chartFlow Process chart

3.3. Travel ChartTravel Chart

4.4. Flow diagramFlow diagram

5.5. Multiple activity chartMultiple activity chart

6.6. Template ModelsTemplate Models

TOOLS USED FOR PREPARING TOOLS USED FOR PREPARING PLANT LAYOUTSPLANT LAYOUTS

3.ii.D.1 String diagram3.ii.D.1 String diagram 1/61/6

String diagram is a useful tool to record the String diagram is a useful tool to record the distance traveled by a worker in the working area. distance traveled by a worker in the working area. The string diagram is a scale plan or model on The string diagram is a scale plan or model on which a thread is used to trace and measure the which a thread is used to trace and measure the distance traversed which has to be distance traversed which has to be minimumminimum by by

•WorkersWorkers•Material orMaterial or•Equipment Equipment

during a specified sequence of eventsduring a specified sequence of events

Observe the clusters of points, pins, turning Observe the clusters of points, pins, turning points. points.

Also observe the grid lines which represent a Also observe the grid lines which represent a measure of the distance between the points.measure of the distance between the points.

Example of a String diagramExample of a String diagramMovement, Transport of tiles from Inspection to Movement, Transport of tiles from Inspection to

StorageStorage

IMPROVED METHODIMPROVED METHOD

Serving dinners in a hospital wardServing dinners in a hospital ward

FPC - FPC - Dinners in a hospital Dinners in a hospital wardward

Original Flow Diagram Inspn and MarkingOriginal Flow Diagram Inspn and Marking

Improved FD of Inspection and Improved FD of Inspection and MarkingMarking

Travel chartTravel chart

Original Flow Diagram Inspection and MarkingOriginal Flow Diagram Inspection and Marking

Improved FD of Inspection and Improved FD of Inspection and MarkingMarking

MAC-Inspn of catalyst in a converter-MAC-Inspn of catalyst in a converter-original methodoriginal method

MAC-Inspn of catalyst in a converter-MAC-Inspn of catalyst in a converter-Improved methodImproved method