Chapter 1... Work Study (Method Study and Work Measurement) 44 INDUSTRIAL ENGINEERING Weightage of Marks = 12, Teaching Hours = 12| 1.1 Industrial Engineering: Definition, Need, Objectives and Scope 1.2 Work Study: Method Study (Motion Study) and Time Study (Work Measurement) 1.3. Method Study: Definition, Objectives, Procedure, Selection of Work 1.4 Recording Techniques: - Process Charts - Outline Process Chart, Flow Process Chart, Two Handed Process Chart/Simo Chart, Muliple Activity Chort, Flow Diagram, String Diagram, Therbligs, Travel Chart 1.5 Werk Measurement — Objectives, Procedure, Time Study, Time Study Equipment. Stop Watch Time Study, Allowances, Calculation of Standard Time, About this Chapter At the end of this chapter, students will be able to: + Apply method study for manufacturing of the given job: + Apply time study for manufacturing of the given job. * Select relevant recording techniques for the given process with justification * Prepare relevant types of charts for the given process using the given recording techniques. ‘+ Calculate standard time for the given activity using work measurement. Industrial Engineering is “a branch of engineering that is concerned with improvement in the system to do things in a better, simplified and organized way". For achieving this, Industrial engineering identifies the areas which faces problem and finds the solutions to solve those problems. Industrial Engineering is defined as "the branch of engineering that is concerned with designing and managing systems to make the best use of industrial resources such as workers, materials, equipment, and information’. The American Institute of Industrial Engineering has defined Industrial Engineering as. "Industrial Engineering is concerned with the design, improvement and installation of integrated system of people, material, equipment and energy. It draws upon the specialized knowledge and skill in the mathematical, physical and sciences together with the principles and methods of engineering analysis and design to specify, predict and evaluate the results to be obtained from such system.” taOf those working in the system. 1.4.1 Need of Indust Engineerin, ‘gineering is concerned reducing Production environment and complying with g money, materias, energy and ay manner, Industrial engineers design systems which enable people and society to need etfciency, effectiveness ane Quality. The industrial engineer play a role to extend the SaPability to operate, inanage and control the overall production system, and to ensu Safety and Well-being uh ines UTES: PINT e ee g ieee beak eed) ae atone eee a ‘her commodities and to utilize it in proper an QUESTIONS 1. What is the need of industrial engineer 2 2._What are the duties (roles) of industrial engineer? QUESTION ineering 2 a ‘What are the objectives of Industrial Engi ‘The objectives of Industrial Engineerin, 19 are: Define proper work methods, Frame policy to give proper incentives to workers, Mentioned belo QUESTIONS of Industrial Engineering 7 The scope of Industrial Engineeri Ensure product quality, delivery dates and cost ig maintained, Determine capacity requirements and subsequent investment o, ret Develop proposals for new projects, Develop long range planning models, typically 5-19 eis Develop budgets and forecasts for operating cost,al Engineering & Quality Control 1,8 Work Study (Method Study and Work Monsurement) 4.2 eracoucTION To WORSE * Work study is defined as ‘a management technique which is employed to improve the activities in the production’. It contributes towards increasing productivity with little or no extra capital expenditure’ + The British standard institution defined work study as "a generic term for those techniques, particularly method study and work measurement, which are used in the examination of human work in ail its contexts and which lead systematically to the investigation Of all the factors which effect the efficiency and economy of the situation being reviewed, in order to effect improvement”, * In simple sentence, work study (Higher investigates the work done in pec an organization and it aims at finding the best and most To determine| efficient way of using available | 66, | [Work measur] [eres resources i.e. men, material, | do the job. money and machines. * The two techniques of work Work st study are method study and s a work measurement. Fig. 1.1: Work study + Method study is concerned with the reduction of the work content of a job or operation, while work measurement is mostly concerned with the investigations and reduction of any effective time associated within. + Method study and work measurement are closely linked to each other as shown in Fig. 1.1. Both, work measurement and method study are themselves made up of a number of different techniques. * From the above discussions it appears that before the time standards are set by work measurement, then method study should be used. But sometimes one of the work measurement techniques (work sampling) is necessary to be used before use of method study. 1.2.1 Work Study Procedure| ‘QUESTION |__1. What is the work study procedure ?_ + For both method study or work measurement, the steps 1, 2 and 3 remains the same. + Step 4 can be developed through method study practice whereas step 5 brings work measurement in use. + The remaining steps are performed depending upon the actions taken in above steps. + The work study procedure consists of the following seven steps. + The steps as shown in Fig. 1.2 below. 1. Selec + Select the job or person for whom work study is to be carried out. . Record: + This step is to record all the facts related to the existing method. +The facts should be recorded with accuracy with the help of charts and diagrams. 3. Examine: + This is a questioning technique to conduct the critical examination.nd when. further que | where 2} way mubjected ¢ what, how, questions 2! practicable: 1s like who, ers to primary rmatives are ‘The primary stage asks question: * Inthe secondary stage the answ determine whether the possible alter Develop: + Considering all the circumstat method and get it approved. Measure: . © Measure the quantity of work involved in the particular time for doing it. Define: * Prepare a written standard practice to define the new method for it. Install: + Install the new method as standard practic watch should be kept so that the problems asso remedied. Maintain: i aera ne nevi method hes been Insallee, Feahould be raaintalied It castes aM ® The workers should not be allowed to slip back into the old method. | proper functioning of the installed method Is ensured by perlodic checks and verificatign omic and ef nces develop the most practical, econ Iculate a standa process and cal and the related time requir itial period of installation, clo e. During the IiH@l,2 method are studied ciated wi Toinereaso product, U —— |» The process or job to be studied. RECORD] Riis aan an bout no rosantial L Baad |_ [tie fects eticaty and in ordered sequenca, Ee | [The most practical, economic and effecve method MEASURE ||} —.] ] he quantity of work : The quantity of work involved and Calculate standard time] Derine | —___, : a ‘The new method so that can always be identified a oe INSTALL ft MAINTAIN, [The method as standard practice, [he sia slandard practice 5 regular routing lecks. " - Fig. 1.2: 1.3 METHOD STUDY 1._Define method study.Industrial Engineering & Quality Control 15 Work Study (Method Study and Work Measurement) + Method Study is defined as ‘the 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’ + The method study which was earlier known as motion study was invested by Frank B. Gilbreth around 1910. Objectives of Method Study’ QUESTION 1._Write any four objectives of method study ? + The method study has following objectives: 1. Improved working processes and standardized products. 2. Improved work place layout and working conditions. 3. Less fatigue to operator and worker. 4. Efficient design of plant and equipment. 5. Improvement in the use of materials, men and machines. 6 Bt Improved ways of doing a job. 2 Method Study Procedure sf QUESTION 1. State basic procedure for carrying out method study. = The method study procedure consists of the following seven steps. None of these seven steps can be excluded. + Strict adherence to their sequence, as well as to their content is essential for the success of any method study. The steps as shown in Fig. 1.3 art 1. Select: ‘+ Select the work for which method study is to be carried out * Consider the economic, technical and human factors while selecting the work. 2. Record: + This step is to record all the facts related to the existing method. * The facts should be recorded with accuracy with the help of charts and diagrams. 3. Examine: * This is a questioning technique to conduct the critical examination. + The primary stage asks questions like who, what, how, why, where and when. + In the secondary stage, the answers to primary questions are subjected to further query to determine whether the possible alternatives are practicable. 4. Develop: + Record the method proposed through critical examination. + Considering all the circumstances develop the most practical, economic and effective method and get it approved. 5. Define: + Prepare a written standard practice to define the process and method, + This step outlines in simple terms the methods to be used 6. Instal + Install the new method as standard practice, During the initial period of installation, close watch should be kept so that the problems associated with the method are studied and remedied. 7. Maintain: + Once the new method has been installed, it should be maintained in its specific form. * The workers should not be allowed to slip back into the old method. + Proper functioning of the installed method is ensured by periodic checks and verifications.such a work, The work selected should not be discontinued or modified in Near future. The early choices for selection are: 1. Bottleneck, which are holding up other Product operations, 2. Movement of material over long distances between shops, 3. Operations involving great deal of man Power, 4. Operations producing lot of scrap or defectives or both, Operations involving repetitive work and liable to Tun for a long time, Operations involving repetitive handling, aaIndustrial Engineering & Quality Cont 47 Work Study (Method Study and Work Measuromer 1.4.2 Technical Considerations| | QUESTION |__1._Explain the technical considerations while selecting the work for method study. + It analyses the technical aspects of the work that is selected. * The method study man should have the technical knowledge about the work selected for method study. * An electrical engineer may not have a sound knowledge in foundry practice, A computer engineer may not rectify the machine shop problem. + Some of the examples in technical considerations are: 1. A ceramic specialist would be able to suggest methods to load the unfired ware into Quality of products is below the standards. Congestion of work on the machine because of its slow speed. ‘The workpiece material is not homogenous. Frequent complaints of machine breakdown or total damage. yawn 1.4.3. Human Considerations QUESTION 1._Explain the human considerations while selecting the work for method study. ‘+ Method study aims for change, but the change should be accepted willingly by the workers. + Mental and emotional reactions to investigations and changes have to be anticipated before selecting the work. + Experience of local personnel and local conditions and awareness can reduce the difficulty. * The workers should be taken in confidence at all the stages of a project and properly explained the benefits of method study. + Method study will be more readily accepted, if it is started on the work that is most unpleasant to workers e.g. lifting of heavy weights. + Following jobs may be first selected for method study: 1. Repeated cases of accidents and health hazardous. 2. Workers complaining of unnecessary and tiring work. 3. Operations involving repetitive work using a great deal of labour. 4. Unsafe, dirty or inconvenient work. QUESTION 1._What are the various recording techniques used in Industrial engineering? + Activities requiring critical examination are recorded properly by the various recording techniques. * The success of a method study depends upon the accuracy with which the facts are recorded, * It is therefore necessary that the records are clear and concise. The facts must be recorded by using one or more of the following techniques of charts and diagrams. 1. Process charts indicating process sequence: (a) Outline process chart (b) Flow process chart (i) Man type - Flow process chart (ii) Material type - Flow process chart (iil) Equipment type - Flow process chart:(c) Two handed process chart 2. Time scale chart that uses time scale: (a) Multiple activity chart 3. Diagrams indicating movements: (a) Flow diagram (©) Cycle graph (e) Travel chart PROCESS CHART 1.6 view of activities involved in the process. 2 various possibilities of It helps to visu A process chart portrays the process wi process in a better way. Process Chart Symbols’ 1. Explain process chart with different symbols 2. Explain symbols used in process chart. ‘As symbols produce a b on charts. symbols are very CO! writing. symbols for various acti These symbols as recommen’ for the following activities: Operation: Operation is represented by a circle. It indicates the main steps in a process, concerned is usually modified or changed Examples of operation are: (2) Operations on machines like turning, (b) Welding, brazing, riveting, fastening. (c) Loading, Inspection: Inspection is represented by @ square. It indicates check for quality. It verifies whether the operation unlike operation, inst Examples of Inspection are: (a) A dimension check with measuring ins (b) Visual inspection: (c) Physical count. ivities are shown i A chart that represents a process is called as 8 Pro In process chart, the major activities and transport etter picture and qui venient and widely understood type of short hand, (p) Simo chart (p) String diagram (@) Chronocycle graph cess chart. of material are recorded to have graphical improvements or alteration in the process: ols in order to understand the: ith the help of sym! QUESTIONS used in it. Jick understanding of the facts, so symbols are ut and save a lot of n Fig. 1.4. ‘ded by ASME (American Society of Mechanical Engineers) are us method or procedure. The part, material or produ during the operation. grinding, drilling etc. unloading, polishing, bending etc. has been correctly carried out or not. ection does not take the material any nearer to completion of a product. \strument,Industrial Engineering & Quality Controt 1.9 Work Study (Method Study and Work Measut 3. Transport: * Transport is represented by an arrow. * In indicates the movement of workers, materials or equipment from place to place. 4. Temporary Storage or Delay: + Itis represented by English alphabet 'D', + It indicates the delay in the sequence of events or objects being laid aside. + The waiting between two consecutive operations is also called as delay. * Examples of delay are: (@) Workpiece lying on floor or in the bin. (b) A letter waiting to be signed. (©) Tools kept in rack. 5. Permanent Storage: + It is represented by an inverted triangle. * It indicates a controlled storage in which material is received into or issued from a store under some form of authorization. + It means that, the item is kept in custody. * To take the item not of permanent storage, some letter or some requisition or order is required that is not required in case of temporary storage. + In order to avoid confusion the word ‘delay’ is used for temporary storage and the word ‘storage’ is used for permanent storage 6. Combined Activities: (a) Operation and Transportation: + It is represented by an arrow ina circle. * Example: Articles being painted they are transported on a conveyor. (b) Inspection and Operation: + Itis represented by a circle inside a square. + Example: A sensor is inspecting the dimension when the part is being machined. i | _ Activity ____ Meaning _ Sil at 2 Operation [ ocereemunealasias Turning on lathe, loading job on | machine, writing a letter etc. Inspection | It indicates checking for Counting, checking a dimension, oi correctness of quality. reading a draft copy of letter etc. Transport | It informs about the movement | Material send for inspetion, | ED omen, material or equipment. | employee going to meet manager | | | “ete. | eagle lel is lee ee i a ees Delay It is stoppage in the sequence | Waiting for part to come from rane D of events. previous section, wait for storage) _| | | authonty’s sign,Example _ ‘ying in godown, tools K weaning Bina € Object is intentionally retained Goods spina ae | re oar Operation is performed during ‘assembly epee 100 ts and transport | | transport. moving on Be ane a | nspection and on de Fi ts and i tion done | Filling milk in packe' seenceieg sot ens checking of leakage etc: Operation | 7 a | inspection .s Chart in Da’ Recording) 'e process chart records major operations and inspections only, chart records operations, inspections, transportations, storages and dela’ ‘ecorded for men or materials or machines. A two-hand process chart reco! worker's both hands simultaneously. A multiple activity chart shows the activities of more than one subject recorded on a com time scale to show their interrelationship. A simo chart records simultaneously on a comma time ! 2 Fig. 1.14: Two handed process chart for sharpening the pencil 1.10.2 Assembly of Nut and Boit| QUESTION 1._Construct two handled process chart for the assembly of Nut and Bolt with summary. ia + Atwo handed process chart for assembling nut and bolt is shown in Fig. 1.15. ‘Two handed process chart Chart begins Both hands free for assembly. Chart ends :__Both hands free after assembly. LEFT HAND RIGHT HAND Description Symbol | Symbol Description Pick up the bolt @ D Idle Hold Vv @ Pick up the nut Hold uv => To left hand Hold Vv @ Assemble Summary: todo, 0410 - |=]. Fig. 1.15: Two handed process chart for assembly of nut and boltLett hand Right hand Peeper |@ | |e Maldberet 1X7] @ | Remove cap Hold barrel WU @ | Pick up ink botte Mold beret | §@7.| @ | Pour ik in bart Hold barrel WZ | ® | keer bottie on table 5 Hold barrel WW | @ | Pick uvcap Hold barrel “1 N71 @)'1 Assemble cop on barrel late BD | © | white by pen to chock Summary = iz RH QO} *JoO]> DB) ded Vi 6 ‘wo handed process chart for fillin le Battery 19 ink in a pen Two handed process chart for rey Hold mobile Put it in proper space Hold mobile Pick bai Ck cover from table lacing the old battery of mobile handset Left Hand Right Hand [ Description Symbol | Symbol Description Pick up mobile @ D Idle Reverse it @ B Jide [ Hold mobile VW @ | Remove back cover I Hold mobile 7 @ | keep on tabie | Hold mobile Vv @ | Remove og battery | Hold mobile WV @ | Keep on tabie Hold mobile W @ | Picknew battery Hold mobile Fit it Properly on Mobile handsetIndustrial Engineering & Quality Control aa7. Work Stu ‘and Work Measu Summary: Ol (Biz V| *|/Ol 8 Fig. 1.17 1.11 MULTIPLE ACTIVITY CHART. QUESTION 1._Explain multiple activity chart with neat sketch. + A multiple activity chart is defined as ‘a chart on which the activities of more than one subject are recorded on a common time scale to show their inter-relationship’. + In the above definition, subject means worker or machine. The multiple activity chart is used when a number of workers work in a group or an individual operator handles two or more Machines, + The multiple activity chart is made to detect idle time enforced on men and machines. + It also establishes a number of machines that can be conveniently handled by an operator. + It also determines number of workers necessary to perform a job involving a team work. * It helps to develop an improved method of accomplishing a task and to have an effective labour cost control + In making a chart, the activities of the different operations or of the different machines are recorded in terms of working time and idle time. The times may be recorded by stopwatch and the times are then plotted in their respective columns as shown in Fig. 1.18. Time Scale] Operator Machine Machine (min) 1 1 Setting Machine I 5 Setting Machine | 10, Idle 20 Setting Machine | 25 Setting Machine | 30, Idle 35 Setting Machine | 40 Setting Machine | 45 Idle 55 Operator working, Machine Working Operator idle, Machine idle Machine being set'gainst a common tims Cycle time of the job. 4. The task to be by a previously 5. Working and idl 2: 3 4. 54 6. In this type, 3. Multi man It shows @ group of workers doing collective Construction work, 4. Multi-man Here the number of The disadvanta Is that it doe: and material. This Is important, be saving in time and ultimately cost. Idle time (min) 25 10 One man hi chart: ‘andles a number of machines, ely one job or operating one machine e.g, rivet Machine chart: '¢ scale which starts with zero and terminates recorded is brok ‘cause if the num diagram are given below Draw the plan of work area to the scale. Mark the relative positions of machines, N Section etc, Draw the path followed by the men or material on the diagram, Indicate the direction of movement on the path, : Use appropriate process symbols on the diagram, Use the serial numbers to mark the various Symbols in, ‘Sequence, stores, inspectioy{Industrial Engineering & Quality Control i Work Study (Method Study and Work Measurement) * A flow diagram is shown in Fig. 1.19. wT |. 1.19: Flow diagram ‘QUESTION What is string diagram? Which steps are followed to construct a string diagram A string diagram is defined as ‘a scale plan or model on which a thread is used to trace and measure the path of workers, materials or equipment during a specified sequence of events’. It is a special form of flow diagram in which a string or thread is used to represent the movement. The purpose of using a string is to measure the distance between the two movements. * Repetitive movement and too many paths make the flow diagram congested and it becomes difficult to understand. The paths which are travelled more frequently calls for critical examination of the work points or movements. 1.13.1 Steps in Drawing String Diagram! * The steps in drawing the string diagram are given below: 1. Draw the scale plan of the work area on a paper. 2. Mark the relative positions of machines, store, inspection, section etc. Attach the complete plan to a soft wood or composition board. Fix the pins on the marked positions and at all the turning Points on the route. Tie the thread or string on the starting point of the movement and wound it to match the path followed by worker or materials. * A string diagram for a_ particular process is shown in Fig. 1.20. Fig, 1.20: String diagramgut a string diagram takes a long time to construct and becomes complicated when a ye of Movements involved are more. Therefore in order to record the complex movement patterns, the travel chart is a sug ‘More Manageable technique, 7 Aostvel chart IS" dernedlas je aepuies record for presenting quantitative data aboy Pen Rants Of workers, materia or equipimare between any number of places over an 9 Period of time’. travel chart, the Path is not tra In ‘The travel chart is always a Sauare box having smaller squares within it. Each small 5 represents a work station, Along with the travel chart, often a bar chart is drawn to represent the frequency of mov to and from the work station, 7. = LJ ge LY] CI co Pe kt et EL 7ece +' ne 2886 bed | oes P2E 28%Industria! Engineering & Quality Contro! 421 Work Study (Method Study and Work Measurement) 1.14.1 Steps in Construction of Travel Chart| b * The steps in construction of travel chart are given below: it Py at no Draw a square grid and mark various departments by numbering on both sides i.e. from left to right and from top to bottom. Mark @ diagonal in the square such that the departments above this diagonal (left to right) represents the places from where the movement takes place and the departments below this diagonal (top to bottom) represents the stations to which the movement is made. As shown in Fig. 1.21 there are 10 x 10 = 100 work stations (departments). For example, to record a movement from station 3 to station 9, the study man comes at umber 3 along the top of the chart and comes vertically down till he reaches a station which is horizontally opposite the number marked 9 on the left hand edge. Here, the study man will mark a cross to indicate the travel from station 3 to station 9. All travels are recorded in the same way, always starting at the top in the square and travelling vertically downwards. Every time in order to make a new record, the study man will go to top of the chart. ‘After the chart is completed, the number of ‘X’ in each vertical and horizontal column are added up and bar charts are plotted in order to provide the frequency of movements to and from each department. 1.15 THERBLIGS y 2s ae 1 ‘QUESTION Sketch the symbols of following therbligs: (1) Transport loaded, (2) Search, (3) Rest, (4) Assemble + Therbligs were suggested by Frank B. Gilbreth so the word ‘Therbligs’ is an anagram of his name. * He differentiated 18 fundamental hand or hand and eye motions of the work cycle. + Every therblig is represented by a symbol, a definite colour and a word to record the same. * The various therbligs alongwith their definitions, symbols and colours are given in Table 1.1. Table 1.4: Ther! Re | Ther Symbol | Code | Colour ‘ 1, .| Search 18 times he was working on the machine. > 4 times he was setting on the machine. > 5 times he has gone for his personal needs. >» 3 times he was doing nothing. » It shows that the worker spends 60% of his time in actual working over'the machine and 10% of the total time he was idle. 1.26.1 Advantages of Work Sampling 1, It involves much less cost as compared to time study. 2. It can be carried out with little training. 3. It can take long time and more number of operations which are difficult to measure by stop watch. 4. Even if the study gets interrupted in between, it does not introduce any error in the result. 5. Observations can be made within the desired accuracy. 1.26.2 Disadvantages of Work Sampling 1. It Is uneconomical to study activities of short duration. 2. It is also uneconomical if the study is for one worker working on one machine. 3. As it does not break tasks into elements, it does not give details of each element. 4. It does not assist in improving work measurement. 5._It does not give the data as accurate as time study. 4 ' + It is a work measurement technique used to determine the basic time by using the synthetic data or on the basis of the past experience when no data is available. + Analytical estimating technique is defined as ‘a development of estimating, where by the time required to carry out elements of a job at a defined level of performance is estimated partly from knowledge and practical experience of the elements and partly from synthetic data’. + It involves the following steps: 1. Collect all the relevant information about the task (i.e. its dimensions, working conditions, machines and tools used). 2. Break the task into number of elements, 3. Select the time for each element from knowledge, experience or synthetic data. 4. Add the time for each element to get the basic time. 5._Add allowance to the basic time to arrive at the standard time. sbyavolds ponducting. time, studies: again ancposin, for itesecsleie neat ate values are available from the previously conducted time studies on other tasks. + It is the work measurement technique to build-up normal time for a new job by adding element times collected from previously held time studies on similar jobs having same elements as possessed by the new job. + The following steps are involved in synthesis: 1. Collect all the relevant information about the task (i.e. its dimensions, working conditions, machines and tools used). 2. Break the task into number of elements like machine elements, constant elements and variable elements, 3. Select the appropriate normal time for each element from the previously available time study data. 4. Add the time for each element to get the basic time. 5. Add allowance to the basic time to arrive at the standard time.times. tay Sb'e 88 stop waleh ie lee NESESR TOTS S time and efforts to determine time values. Saini tis ay hah time studiyiig tr kedps Heerlen e values are known is very helpful in Planning and control as the tims Production — f: dian " i TEM ess E nie ar sort ROTOR RI eS established for ¢, Work measurement fechnique where tim 1 of performance’. USed to build-up the time for @ job at a defined level of uy assembly jobs, ey '@ jobs involving Machining work, maintenance wor se 4 NG varieties of tasks, . Aawrovle film: (Micromotion study), Analyze the fim, na te down the tj the form of a table 4. me taken to complete each element and compile the chart, Normal time for ny new task can be determined by breaking the task into movements, 5. Note the time for £8ch motion fro, involved in'the task ©. Add proper ai ™ the table and add the time values for all the basic llowances to the basic time to arrive at the standard time, 1.29.2 Advantages of PMTS 2 Reliminates inacoussers—e ed with time stugy— Methods Time Measurement (MTM) is a maetermined motion time primarily in industrial settings to analyse the methods Used to performs any manual eo task and, as a byproduct of that analysis, set the Standard time In which a worker complete that task. The unit in which movements are Measured for m 1 hour = 100,00 © ? Explain, nal delays, t5 ove; obtain standary time, NaN average Pace, idable delays. tastes are added to the normal time to It is not possible for an operator to maintai; of the day. Persoy Fcome fatigue ihe is Working for every | ieIndustral Enginoering & Quality Contro! 4.83, Work Study (Method Study and Work Measurement) * So he has to take out time to overcome fatigue, for his personal needs and for reasons beyond his control. + The various types of allowances are: 1, Relaxation allowance 2. Contingency allowance 3. Policy allowance 4, Special allowance + The relaxation allowances which are intended to help the operator to recover from fatigue are the only essential allowances added to the basic time. Other allowances are applied under certain conditions only 1.30.1 Relaxation Allowance) * It is an addition to the basic time intended to provide the worker with the opportunity to recover from the physiological and psychological effects of carrying out specific work under specific conditions and to allow attention to personal needs. + Relaxation allowance has two major components: 1. Personal allowance 2. Fatigue allowance 1. Personal Allowance: + These are the allowances provided to the worker in order to satisfy his personal needs like drinking water, visiting toilets, trip to dressing rooms, smoking, tea breaks etc. * When the working conditions are favourable, 5% allowance is added for men and 7% for women. 2. Fatigue Allowance: + Fatigue is defined as 'a physical or mental weariness existing in a person that affects his ability to perform work. + Fatigue is the result of unhealthy working condition, physical exertion, inconvenient postures, concentration work etc + The common figure of 4% of the basic time is considered as fatigue allowance. However it may vary from light to heavy work 4.30.2 Contingency Allowance * It is defined as delay allowance; it is not desired from either side, (i.e. from management side or from worker side) but is still required. + If the contingency allowance exceeds 5%, then the method should be improved. * Contingency allowance is defined as ‘a small allowance of time included into the work content of the task to compensate the operator for the time lost due to legitimate interruptions and delays which are uneconomical to measure because of thelr infrequent and irregular occurrences’. + Some examples of contingency allowance are: (i) Breakage of tool or waiting for part to come. (ii) Power failure of small durations. (ili) Daily maintenance by maintenance department. (iv) Interruptions from the foreman, time study analyst etc. (v) Obtaining special inspection devices. 1.30.3 Policy Allowance! * A policy allowance is an increment, other than bonus increment, applied to standard time to provide a satisfactory level of earnings. * Policy allowance is a management decision and cannot be demanded by a worker. It is not the part of time study.of the op 'Y be given for any activities which are not bene Part of the o, re essential to the Satisfactory performance of the work. examples Of special allowance are: ks dl owance to cover the time required for preparing a machine for ee a oe be allowed when the Production of a props ion alloy wance, to adopt a new metho SOLVED NUMERICAL PRO! LEMS ON STANDARD TIME Normal time per article = 1.5 minutes Allowances = 480-400 = 80 minutes BP Allowarices2= 805 coleianye of normal time Therefore standard time Per article =1.5 41.5 = 0.25 minutes Standard time = Basic time + Allowance = 1.25 + 0.25= 1.5 minutesBasi i Ic time for the ‘Peration = Observed time x Eereeh rating = Lib 6320 8 minutes 1.8 * 15% of basic time = 48248 _ 9.27 minutes ~ Basic time + allowance = 1.8 + 0.27 = 2.07 minutes 2.64 minutes 2.61 3.35 1.20 0.53 Basic time of the job (a) a (b) Standard time of the job lowances 94 minutes = Basic time + alt s Js. = 10.94 + 795 (0.971) = 12.69 minutes‘Industrial Engineering & Quality Control 4.39 Work Study (Method Study and Work Measurement) ‘ Rating as | = Observed time x “T5p, 85 = 04x 7957 0-34 I 1.6 80. 1.28 tein ML 1 90 0.9 7 2.4 5 1.56 Normal time in minutes 4.08 Normal (or basic) time per piece = 4.08 minutes ~() Rest and Personal Needs Allowance = 74%; x 4.08 = 0.612 minutes (2) Contingency Allowance = 755 x 4.08 = 0.0816 minutes ae) Standard time per piece = (1) + (2) + (3) 4.08 + 0.612 + 0.0816 Problem 1.12: A particular activity 01 x Calculate standard time for the activity Te Elements see Observed time (min) 1.20 Rating factor (%) 80 Total Allowances (%) ers Solution: (a) For element I: ti Basic time for the operation = Observed time x ga HoUna a 1.20 x yh = 0.96 minutes Allowance = 22% of basic time — 22x0.96 eelOOmal Standard time = Basic time + Allowance 0.96 + 0.211 = 1,171 minutes .211 minutes (b) For element II: Rating 90. Observed time x Standard rating = 0-5 * igp = 0.45 minutes Basic time for the operation Allowance = 19% of basic time = = 0.0855 minutes Standard time = Basic time + Allowance = 0.45 +0.0855 = 0.3555 minutes. (c) For element III: Basic ime forthe operation = Observed time x seangarg rang = 0-80 x 7 = 0.6 minutes 20% of basic time = 2008 _ 9 4 minutes Allowance Standard time = Basic time + Allowance = 0.6 + 0.12 = 0,72 minutes Standard time for the activity = Standard time of element (I + II + III) = 1.1712 + 0.5355 + 0.72 = 2.4267 min aeeduction to Work Study: . iv: : ane Sentence, wore study investigates the work done in an Seen ae ait Ma the best and me jlable resources i.e. men, a, mo and machines St efficient way of using availa «WO techniques of wo, surement, rk idy and work mea Method stua study are method study Tr ls the systematic Heerding and critical examination of existing and proposed ways of qg cui #5. means of do costs, veloping and applying ea: sier and more effective methods a nd red method study, the economic considerations, 's should be considered, Recording Techni ques: Process Chart: * A chart that represents a Process Is called:as.a process chart, . , the major activities an, view of activities involved in the Process, Tt helps to visualize various Possiblties of improvements op alteration in the Process, Process Chart Symbols: ‘s 4 transport of material are recorded to have a graphi Operation is represented by a circle, Inspection is represented by a square. Transport is represented by an arrow, Temporary storage or delay is re ttline Process Chart: An outline process chart is a process chart that give main operations and inspection, in a sequence. This chart contains only the symbols of operation ang A delay and storage are not included, ection. The Activities like trat eS an oyIndustrial Engineering & Quality Control 1.41 Work Study (Method Study and Viork Measurement) Flow Process Chart: * A flow process chart is a process chart which sets out the sequence of the flow of a product through the various departments by recording the event using the appropriate process chart symbols + Man type flow process chart records the activities of an operator. + Equipment type flow process chart records the manner in which the equipment is used. * Material type flow process chart records how material is handled or treated. Two Handed Process Chart: + The two handed process chart is a process chart in which the activities of a worker's hands are recorded in their relationship to one another. + The chart records the activities of the left and right hand of an operator while he is doing a job. Multiple Activity Chart: * A multiple activity chart is a chart on which the activities of more than one subject are recorded on a common time scale to show their inter-relationship. + The multiple activity chart is made to detect idle time enforced on men and machines. * It also establishes a number of machines that can be conveniently handled by an operator. * It also determines number of workers necessary to perform a job involving a team work. Types of Multiple Activity Chart: * Man=machine chart: One man handles only one machine. + Man multimachine chart: One man handles a number of machines. Multi man chart: A group of workers doing one job collectively. Multi man machine chart: The number of persons works on a computer system. Flow Diagram: + It is a scaled diagram which shows the relative position of the machines, inspection section, stores and work the paths followed by men and materials. String Diagram: + Astring diagram is a scaled plan or model on which a thread is used to trace and measure the path of workers, materials or equipment during a specified sequence of events. Travel Chart: * A travel chart is a tabular record for presenting quantitative data about the movements of workers, materials or equipment between any numbers of places over any given period of time, + In travel chart, the path is not traced but the number of movements are indicated. Work Measurement: + It is the application of techniques designed to estiablish the time for a qualified worker to carry out a specified job at a definite level of performance. * The work measurement technique is carried out, after the proposed method of doing the work has been devised by using method study. + It provides the management with a standard time for an operation. Work Measurement Procedure: * Select the work for which time study is to be carried out. + Record all the relevant data related to the circumstances in which the work is done. * Examine the data critically to ensure that the most effective methods and motions are used. * Use work measurement technique to measure the time required for each element. * Determine the standard time for each operation, by adding the suitable allowances. * Define the series of activities and method of operation for which the time has been found.industrial Enginooring & Quality Cor 1.43 Work Study (Method Study and Work: Work Sampling: + In work sampling a large number of observations are conducted at random intervals of time and the state of each member of the group is studied. * It Is defined as ‘a technique in which the observations are recorded and the per cent of observations recorded for a particular activity or delay is a measure of the percentage of time during which that activity or delay occurs’. Analytical Estimating: + It is a work measurement technique used to determine the basic time by using the synthetic data or on the basis of the past experience when no data is available. * Analytical estimating technique is defined as 'a development of estimating, whereby the time required to carry out elements of a job at a defined level of performance is estimated partly from knowledge and practical experience of the elements and partly from synthetic data’. ‘Synthesis from Standard Data: + It avoids conducting time studies again and again for those elements for which exact time values are available from the previously conducted time studies on other tasks. + It is the work measurement technique to build-up normal time for a new job by adding element times collected from previously held time studies on similar jobs having same elements as possessed by the new job. Predetermined Motion Time System: * It Is defined as ‘a work measurement technique where times established for basic human motions are used to build-up the time for a job at a defined level of performance’. Allowances: + It is the time allowed to the worker for personal delays, to overcome fatigue and for unavoidable delays. * Allowances are added to the normal time to obtain standard time. Relaxation Allowance: + It is an addition to the basic time intended to provide the worker with the opportunity to recover from the physiological and psychological effects of carrying out specific work under specific conditions and to allow attention to personal needs. Contingency Allowance: + It is defined as delay allowance; it is not desired from either side, (i.e. from management side or from worker side) but is still required Policy Allowance: * A policy allowance is an increment, other than bonus increment, applied to standard time to provide a satisfactory level of earnings. Special Allowance: + Special allowances may be given for any activities which are not normally part of the operation cycle, but are essential to the satisfactory performance of the work. ered tes 1. Explain the term work study. 2. What is method study? State its objectives. 3. Explain the method study procedure. 4. What factors should be considered while selecting the work for method? 5. What are the various recording techniques used in method study? 6. What is a process chart? Explain with symbols. 7. Explain the symbols used in process chart. 8. What is outline process chart? Explain its objectives, 9. Draw an outline process chart to change the car battery. 10. Draw an outline process chart to check the dimension of a shaft. 11. Draw an outline process chart to change the SIM card of a mobile phone. 12. Draw an outline process chart to change the punctured tyre.