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October 03 Lotfi K. Gaafar^^1
Lotfi K. Gaafar
Method Study
Based on Introduction to work study. 3rd ed. International Labor Office, Geneva, 1992.
MENG 344
Work Analysis and Design
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Work Study
Work Study is the systematic examination of the
methods of carrying on activities so as to
improve the effective use of resources and to set
up standards of performance for the activities
being carried out.
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Method study examines the way a task (changing the clutch on a
car, preparing a flower bed for planting, cleaning a hotel room) is
done. The industrial engineer has an eye on operational
efficiencies and costs, quality of processes, service reliability,
staff safety etc. Method study techniques are applicable from
factory/workshop manufacturing to cabin crew activities on an
international flight and office clerical work.
Method Study
A collection of techniques used to examine work - what is done
and how it is done - so that there is systematic analysis of all the
elements, factors, resources and relationships affecting the
efficiency and effectiveness of the work being studied.
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Management
Supervisor Workers
Work Study Specialist
The Human Factor in The
Application of Work Study
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Work Study and the Supervisor
The importance of the supervisor:
l Mostly affected by work study.
l A personal challenge.
l Responsibilities are taken away.
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Do’s and Don’ts
l Never give a direct order to a worker.
l Always refer worker’s questions to the supervisor.
l Never express opinions to workers.
l Don’t allow worker’s to get you to alter decisions made by the
supervisor.
l Seek the supervisor advice whenever possible.
l Always be introduced to workers by the supervisor.
Work Study and the Supervisor
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Work Study and the Worker
ß Work study improves industrial relations:
l Workers feel that the management cares for
them.
l Workers discover that there are managers who
highly understand their job.
l Improving the feeling of confidence.
l Workers are more able to carry out their jobs.
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Work study and the Worker
ß Why workers resist the work study:
l It will change their familiar work methods.
l Many workers resent being timed.
l Fear of being fired.
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Problem Solving
ß Recommendation for action
l written reports to senior managers
l presentations to senior managers and shop floor
employees
l development of soft skills, listening,
negotiating,
ß Marketing recommendations
l target relevant groups
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How do we measure performance?
ß Profit
ß Financial measures
ß Productivity – output/input ratios
ß Cycle time
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Possible Performance Measures
ß Quality expressed as % scrap value, % returns, %
downtime
ß Costs expressed as inventory turnover, value added
to incoming material
ß Delivery expressed as % on time delivery, cycle
time
ß Flexibility as Average number of setups /day, % of
common parts/product
ß Innovation as % sales from products introduced in
last 3 years
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Method Study
Select
Record
Examine
Develop
Evaluate
Define
Install
Maintain
To Simplify the job and develop more economical methods of doing it
the job to be studied
by collecting data or by direct observation by Challenging purpose, place, sequence, and method of work new methods drawing on contributions of those concerned
results of different alternative solutions
new method and present it new method and train persons in applying it and establish control procedures
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Select – Technical Considerations
ß Extensive paperwork
ß Repetitive work (automation)
ß Hazardous work
ß Inconsistent quality
Select Record Examine Develop Evaluate Define Install Maintain
Desire to acquire more advanced technology
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Select – Human Considerations
ß Satisfaction level
ß Start with non-controversial jobs
ß HSE
Select Record Examine Develop Evaluate Define Install Maintain
Workers satisfaction/resentment
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Select – Limiting the Scope
ß One operation or a sequence
ß The whole operation or part
ß Which aspect: worker, materials,
equipment, … etc.
Select Record Examine Develop Evaluate Define Install Maintain
Setting boundaries and determining content
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Select – Possible Results
ß Increased production rate
ß Reduced cost
ß Less labor, materials, or equipment
ß Improved quality
ß Improved safety
ß Reduced scrap
ß Improved standards of cleanliness
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Symbols
Operation (Make ready, Do, Put away)
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Symbols
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Symbols
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Symbols
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Outline Chart Face, turn, cut Face opposite end Dimension and finish Straddle mill four flats Remove burr Final inspection of machining Degreasing Cadmium plating Final check
Face both sides Drill hole Final check
Assemble and drill
Turn shank Remove chip Dimensions Degreasing Cadmium plating Final check
Fit stop pin
Final check Switch Rotor
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Outline Chart
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Flow Chart
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Flow Chart
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Flow Chart
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
Multiple activity Chart
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Record- Example
Select Record Examine Develop Evaluate Define Install Maintain
String Diagram
