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Definition:

“It is a 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.”

WHY:

The improvement of processes and procedures.The improvement of factory, shop and workplace layout.The improvement of the design of plant and equipment.Economy in human effort and the reduction of unnecessary fatigue.Improvements in the use of materials, machines and manpower.The development of a better physical working environment.Improvement of quality of the products.

METHOD STUDY

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Recording Techniques in Method study

Outline process chart Flow

process chart

Material type chart

Machine type chart Two -

Handed process chart

Using a time scale

Multiple activity chart

Simo chart

P.M.T.S. chart

Man type chart

Indicating Process

Sequence

Diagrams indicating

movements

String Diagram

Flow Diagrams

Travel Chart

Chrono-cycle Graph

Cycle Graph

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Process Chart SymbolsProcess 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.

2.Inspectio2.Inspectionn

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

1.Operatio1.Operationn

3.Transpor3.Transportt

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

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4.Temporary Storage or 4.Temporary Storage or DelayDelay

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

record until required. record until required.

5.Permanent 5.Permanent StorageStorage

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

6.Combined 6.Combined ActivitiesActivities

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 an from a store under some form of authorization; or an item is retained for item is retained for reference purposes.reference purposes.

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Figure: 6

Outline Process ChartOutline Process Chart

While preparing the outline process chart we use Symbols of Operation and Inspection

A brief note of the nature of each operation is made beside the symbol

In an outline process chart, only the principal operations and the inspections carried out are recorded to ensure effectiveness

Definition: An outline process chart is a process chart giving an overall picture by recording in sequence only the main operations and inspections.

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Example: Outline process chart of plywood manufacture is given 

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Flow process chartsFlow process charts

Definition: Flow process charts are graphic representations of the sequences of operations, transportation, inspections, delays and storages occurring during a process or a procedure and include information considered for analysis such as, time required and distance moved.

To develop an understanding how a process or work happening and clearly documenting how a particular job is done, in addition of that mapping a process in flow chart format helps us where the process can be improved.

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Material or product type.Man type.Machine type or equipment.

Material or product type flow process chart:-Records what happens to the material or product i.e. the changes the material or product undergoes in location or condition (includes operation and transportation).

Man type process flow process chart:-Records the activities of worker or operator i.e. what a worker or operator does. In this type of chart usually storage term is not applicable.

Machine or equipment type flow process charts:- Records the manner in which a machine or an equipment is used.

Types of Flow Process ChartsTypes of Flow Process Charts

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STANDARD FORMATS USED FOR FLOW PROCESS CHARTSTANDARD FORMATS USED FOR FLOW PROCESS CHART

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Job:- Writing a letter using a shorthand typist

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Example: Collection of materials from store (Man Type)

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Material type flow process chartMaterial type flow process chart

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Machine type flow process chartMachine type flow process chart

Job : Assembly of flange at shrink fitting m/c.

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Two Hand Process Chart

Two-Handed Flow Process Chart, is a motion study where the study is done to analyse the motions used by the worker in performing an activity. In this chart the activities of a worker’s hands (or limbs) are recorded in their relationship to one another. A Two-Handed Process Flow Chart individually shows the movement of each hand in a manual process. It is typically used for repetitive operation when analyzing a manual assembly process, to help make it easier to perform. 

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Why:The objective of this investigation is to eliminate or reduce the unwanted motions and to arrange the remaining motions

in a best sequence.

How: A two-handed process chart is made up of two columns in which the activities of the left hand and right hand and the appropriate symbols are respectively recorded in sequence. The activities of the two hands are inter-related by aligning the symbols on the chart so that movements by both hands appear opposite to

each other. Additional columns can be designed to record the activities of the other parts of the body whenever necessary.

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Operation An operation occurs when the hand grasps, releases or assembles tool, material, component etc.

Transport Transport occurs when the hand moves from one position to another at the work place.

Delay Delay occurs when the hand is Idle in the sense that it is not performing any activity.

Hold The term storage is not used in connection with the two handed process chart. Instead the symbol is re designated as hold. A hold occurs when the hand holds an object so that the other hand may be able to do something to that object.

Inspection This symbol is not generally used in this.

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Standard format of a Two-handed process flowchart

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Fig. 1. Example of a Two-handed process flowchartFixing Screw on a Assembly

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Fig. 1. Example of a Two-handed process flowchartFixing Screw on a Assembly

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A Chart in which the activities of more than one item are recorded on a common time scale to show their inter-relationship. Man machine chart is the type of multiple activity charts.

TYPES:Man - Machine chart: One man handling one job or one machine. Man - Multi machine chart: One man handling a numbers of machines. Machine Multi - man chart: A group or gang doing collectively one job as in riveting. Multi – Man - Machine chart: A number of persons working on a computer system.

MULTIPLE ACTIVITY CHART

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MULTIPLE ACTIVITY CHARTDefinition:

A Multiple activity chart is a form of process chart recording the related sequence of work of a number of operators and/or machines on common time scale. In it, the activities of more than one item, worker, machine or equipment are recorded on a common time scale to show their inter relation ship.

Why:

Multiple Activity Charts are very useful tool for understanding the flow of work in a cyclic process and as a consequence understanding which resource is controlling the overall progress of the work.

The tool can be used to model different scenarios to determine the optimum mix of resources for the work. 23

Multiple activity chart brings out the comparative utilisation of men and machines very clearly and helps to synchronise the various activities and improve the situation. It is a useful tool for planning team work and determining the staffing pattern.

The multiple activity charts shows up clearly the periods of ineffective time and by rearrangement of work it becomes possible to eliminate or reduce the injective time.

How:Activities of the machines are recorded in relation to that of the operator, the chart is sometimes called as the man machine chart; This is only a special variant of the multiple activity chart

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TIME (MIN)

MAN MACHINE TIME (MIN)

0.2 Remove finished casting cleans with compressed air

IDLE 0.2

0.4 Gauge depth of slot on surface plate

IDLE 0.4

0.8 PLACE in a box obtains new casting

IDLE 0.8

1.0 Cleans machine with compressed air

IDLE 1.0

1.2 Locates castings in fixture, starts machine

IDLE 1.2

1.4 IDLE Cutting slot 1

1.4

1.6 IDLE Cutting slot 2

1.6

1.8 IDLE Cutting slot 3

1.8

2.0 IDLE Cutting slot 4

2.0

Example on Man Machine Chart (Present Method)

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Man – Machine

Working Time (min.)

Idle

Time

(min.)

Utilizati

on

(%)

MAN 1.2 0.8 60%MACHINE 0.8 1.2 40%

CYCLE TIME(MIN)= 2.0

EXAMPLE ON MAN MACHINE CHART(Summary of Present method)

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TIME (MIN)

MAN MACHINE

TIME (MIN)

0.2 REMOVED FINISHED CASTING CLEANS WITH COM PRESED AIR

IDLE 0.2

0.4 CLEAN MACHINE WITH COMPRESED AIR

IDLE 0.4

0.6 LOCATEES A NEW CASTING IN A FIXTURE START MACHINE

IDLE 0.6

0.8 BREAKS SHARP EDGES WITH FILES CLEANS WITH COMPRESSED AIR

CUTTING SLOT 1

0.8

1.0 GAUGE DEPTH OF SLOT ON SURFACE PLATE

CUTTING SLOT 2

1.0

1.2 PLACES CASTING IN A BOX PICKS UP NEW CASTING AND PLATE BY MACHINE

CUTTING SLOT 3

1.2

1.4 IDLE CUTTING SLOT 4

1.4

Example on Man Machine Chart (Improved Method)

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EXAMPLE ON MAN MACHINE CHART(Summary of Improved method)

CYCLE TIME(MIN)= 1.4

Man – Machine

Working Time (min.)

Idle

Time

(min.)

Utilizati

on

(%)

MAN 1.2 0.2 85.7%

MACHINE 0.8 0.6 57.0%

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CYCLE TIME (MIN)

MAN IDLE TIME(MIN)

MACHINE IDLE TIME ( MIN)

PRESENT METHOD

2.0 0.8 1.2

IMPROVED METHOD

1.4 0.2 0.6

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Micro motion study is the study of fundamental element or subdivision of an operation by means of a motion picture camera and a timing device which accurately indicates the time interval on motion picture film.

Micro motion study provides a valuable technique for making minute analysis of those operation that are short in cycle contain rapid movement and involve high production over a long period of time. For example. Sewing of garment, assembly of small parts.

Micro motion study

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Applicable for operations with very short cycles which are repeated thousands of times.

Goes into greater details to determine where movements and efforts can be saved and to develop the best possible patterns of movements.

Enables operators to perform the operation repeatedly with minimum effort and fatigue.

The technique used for this typically involves filming the operation and hence is known as micromotion study.

Examples of operators studied could be cashier in the bank – routine job of taking payment slips from customer and issuing cash!

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Based on the idea that human activity can be divided into movements or group of movements (therbligs) according to the purpose for which they are made.

The therbligs cover movements or reasons for the absence of movement.

Each therblig has specific color, symbol and letter for recording purposes.

Therbligs refer primarily to motions of the human body at the workplace and to the mental activities associated with them.

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They permit a much more precise and detailed description of the work than any other method described.

Considerable practice is required in identification of therbligs before they can be used for analysis with confidence.

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Main advantages of films over visual methods are: Permit greater detailing than eye observation; Provide greater accuracy than pencil, paper and stop watch; More convenient; Provide a positive record; Help in the development of the work study person.

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Objective of Micro motion study

1. To find most efficient way of doing work2. Helps to study repetitive short cycle operation

which cannot be studied by ordinary method.3. To train operator regarding motion economy.4. It is permanent means of keeping record of

method.5. It assists in research project in the field of work

study6. It helps to study complex activities of short

duration performed with extreme rapidity.

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Procedure/ Step in micro motion study1. Filming the operation to be studied.2. Analyzing the film.3. Charting the result of analysis.4. Developing and improve method.

Filming :-The filming speed is 16 frames per second with a 16 mm movie camera.

Film Analysis:-1.A Projector is used for analysis purpose.2. Projector runs the films very slowly and film can be stopped & reversed whenever required.

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2. Movie Camera.

EQUIPMENT REQUIRED

1. 16 mm film. 3. wink counter.

Exposure meter. Motion picture projector with screen37

A record of path of movements, usually traced by a continuous source of a light on a photograph.

The path of movement of a hand, may be recorded on a photograph by putting a ring carrying small light on worker’s hand.

A path of light resembling a white wire is seen. Later it is used with a stereoscopic camera to

show the path in three dimensions .

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Light (bulb) attached to the hand

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This is a development of the cycle graph by interrupting the flow of current so as to obtain, in the resulting sequence of flashes, a record of the time and direction of the motions under observation. The resulting image was a chronocyclograph.

The path of light appears as a series of pear-shaped dots, the movement being in the direction in which the dots point.

The spacing between the dots indicate the speed of movement and show acceleration and deceleration.

This is done by using a turning fork, which is vibrating at a known speed, and connected with a “make and break” contact.

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Diagrams Diagrams gives pictorial view of the layout of workplace

on which locations of different equipment, machines etc. are indicated.

The movement of subject(man or machine) is then indicated on the diagram by a line or a string.

The diagram are valuable in highlighting the movement so the analyst can take steps to simplify or reduce it so as to obtain saving in time.

The most commonly used method study diagrams are: o Flow diagramo String diagramo Travel charto Cyclegraph and Chronocyclegraph

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Flow diagram

It’s a top view of the work area correctly indicating the positions of machining and other locations affecting the movement of subject.

Therefor it gives “on-the-spot observation” of the paths of movement of product sometimes using symbols of process charts.

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A scale plan or model on which a thread is used to trace and measure the path of workers, material or equipment.

A thread is used to measure distance. Necessary that the string diagram be drawn correctly to

scale, whereas regular flow diagram can be drawn only approximately to scale.

Thus, string diagram and flow chart can give clearest possible picture of what is actually being done.

String diagram can be used to plot movements of material to know how far the materials travel.

Most commonly, the string diagram is used for plotting the movements of workers.

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0 10ft

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Examples

START

END

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Travel chart String diagram is good to explain movements and

critical examination buto it takes longer time to get constructed ando many movement along complex paths may

lead to a diagram with maze of crisscrossing line.

Therefore, when movements are very complex travel chart is quick and more effectively manageable recording technique.

How is it made ?o A travel chart is a tabular record for pressing

quantitative data about the movements of subject between any numbers of places a over a given period of time.

o This chart is a square table and each square within table represents a station.

o It has number of rows and columns equal to the number of stations that can be visited by the subject.

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