Industrial Work Study

Unit 3: Work Sampling

Introduction to Work Sampling
What is Work Sampling?
Work sampling is a statistical technique used to estimate the proportion of time
workers or machines spend on different activities. It involves taking random
observations at intervals and analyzing the collected data to assess productivity,
measure work efficiency, and establish standard time.
Unlike time study (which requires continuous observation with a stopwatch), work
sampling is based on periodic checks, making it a less intrusive and cost-effective
method.

Objectives of Work Sampling

The primary objectives of work sampling are:
1. Measure Productivity:
o Helps determine the proportion of time a worker or machine spends
on productive work versus idle time.
2. Establish Standard Time:
o Used to set standard time for various tasks by calculating the
proportion of time spent on different activities.
3. Identify Bottlenecks:
o Helps recognize delays, inefficiencies, and areas for improvement in
workflow.
4. Reduce Observational Bias:
o Since work sampling involves random observations, it eliminates
continuous observation pressure and minimizes bias.
5. Optimize Workforce Allocation:
o Assists in better workforce planning by understanding time
distribution among different activities.

Basic Procedure of Work Sampling

The work sampling study follows a structured approach to ensure statistical
accuracy and reliability.
Step 1: Define Objectives
 Determine why the study is being conducted (e.g., machine utilization,
worker efficiency, or setting standard time).
Step 2: Select the Work Activity
 Identify the specific activities, processes, or machines to be observed.
Step 3: Define Observation Categories
 Classify tasks into categories such as:

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 1. Effective Work (Productive Time)
2. Ineffective Work (Delays, Waiting, Setup Time)
3. Idle Time (Breaks, Machine Downtime, Personal Time)
Step 4: Decide the Sample Size
 The number of observations required is determined statistically using the
formula: n = \frac{p(1 - p) (Z / e)^2} where:
o ppp = estimated proportion of work activity
o ZZZ = standard normal value for confidence level
o eee = allowable error
Step 5: Schedule Random Observations
 Observations should be made at random intervals to avoid predictable
patterns and bias.
Step 6: Collect and Record Data
 Each observation is recorded as either work, idle time, or delay.
Step 7: Analyze Data
 Calculate the percentage of time spent on different activities.
 The standard time is determined based on the observed productive time.
Design of Work Sampling Study
To ensure the accuracy and reliability of a work sampling study, proper planning
and design are essential.
Key Elements in Designing a Work Sampling Study:
1. Scope and Objective:
o Clearly define the purpose of the study (e.g., analyzing machine
utilization, measuring workforce productivity).
2. Selection of Work Area and Subjects:
o Identify which workers or machines will be studied.
3. Selection of Sample Size:
o More observations increase accuracy. Generally, 1000-2000
observations provide reliable results.
4. Training of Observers:
o Observers must be trained to classify observations correctly.
5. Data Collection Plan:
o Observations should be randomly distributed over different times
and shifts.

Conducting a Work Sampling Study

The study is conducted in the following phases:
1. Planning Phase
 Define study objectives
 Identify observation categories

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  Choose workers/machines for study
2. Data Collection Phase
 Conduct random observations
 Record work and idle time
3. Analysis and Interpretation
 Compute the percentage of time spent in various activities
 Establish normal time and add allowances to determine standard time
4. Reporting & Recommendations
 Present findings in reports, graphs, or charts
 Suggest improvements for efficiency

Flowchart for Work Sampling Study

Below is a simple flowchart representing the work sampling procedure?
START
↓
Define Objectives
↓
Select Work Area and Activities
↓
Determine Sample Size & Observation Plan
↓
Collect Random Observations
↓
Classify Data (Productive / Non-Productive)
↓
Analyze Data & Compute Standard Time
↓
Present Findings & Recommend Improvements
↓
END

Establishment of Standard Time Using Work Sampling

Standard time is the total time required to complete a task under normal
working conditions.

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Applications of Work Sampling
✅ Manufacturing & Production:
 Used to measure machine utilization and worker productivity.
✅ Healthcare Industry:
 Helps analyze nurse and doctor activities to optimize hospital efficiency.
✅ Retail & Services:
 Evaluates customer service efficiency and cashier performance.
✅ Construction Industry:
 Assists in identifying labor inefficiencies and improving project timelines.

Advantages of Work Sampling

✅ Less Effort & Cost-Effective:
 No need for continuous observation like time studies.
✅ Applicable to Multiple Workers/Machines:
 Can study multiple workers simultaneously.
✅ Reduces Bias:
 Random observations prevent observer influence.
✅ Useful for Non-Repetitive Tasks:
 Unlike time study, which is suitable for repetitive tasks, work sampling is
effective for long-cycle or variable tasks.

Limitations of Work Sampling

❌ Not Suitable for Short-Cycle Tasks:
 Requires long observation periods, making it ineffective for short-duration
tasks.
❌ Needs Large Sample Size:

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  A higher number of observations is required for accuracy.
❌ Requires Proper Training:
 Observers must be trained to avoid misclassification of activities.

Case Study: Work Sampling in a Manufacturing Plant

Scenario:
A manufacturing company wants to measure how much time its employees spend
on productive work versus idle time to improve efficiency.
Process:
1. The company conducts random observations of workers throughout the
day.
2. Data is classified into working time, idle time, and setup time.
3. After analyzing 2000 observations, the study reveals:
o Productive work: 75%
o Idle time: 15%
o Setup time: 10%
Outcome:
Based on these results, the company:
 Reduces idle time by improving workflow.
 Reorganizes shift schedules to increase productivity.
Conclusion
Work sampling is a powerful tool for analyzing productivity and setting standard
time. It provides statistical accuracy with minimal effort, making it widely
applicable in industries such as manufacturing, healthcare, and retail.
Design of Work Sampling Study
1. Introduction to Work Sampling Study
Work sampling is a technique used to estimate the proportion of time spent on
different activities by observing workers or machines at random intervals. It helps
determine standard time, identify inefficiencies, and improve productivity.
Key Features of Work Sampling:
 Based on statistical probability.
 Uses random observations over time.
 Requires a large sample size for accuracy.
 Suitable for indirect, non-repetitive, and managerial work.

2. Objectives of Work Sampling Study

1. Determine Productivity: Measure how much time workers/machines spend
on productive and non-productive tasks.

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 2. Estimate Standard Time: Establish a standard time for completing tasks by
analyzing work patterns.
3. Identify Inefficiencies: Detect bottlenecks, unnecessary delays, and areas
for improvement.
4. Optimize Resource Allocation: Help in workforce planning by
understanding work distribution.
5. Evaluate Performance: Compare actual work performance with expected
performance.
6. Improve Work Methods: Provide data for improving existing work
methods and reducing idle time.

3. Steps in Designing a Work Sampling Study

Step 1: Define the Objective of the Study
 Clearly outline the purpose (e.g., productivity analysis, machine utilization).
 Decide whether the study is for a single worker, a group, or a process.
Step 2: Select the Work Area and Activities
 Identify the departments, machines, or workers to be observed.
 Classify activities into categories like productive, non-productive, and idle
time.
Step 3: Determine the Sample Size

Step 4:Establish a Random Observation Schedule

 Ensure randomness to eliminate bias.
 Use a random number table or software to generate observation times.
Step 5: Conduct Observations
 Visit the workplace at random intervals.
 Record what the worker or machine is doing.
 Categorize activities accurately.
Step 6: Analyze the Data
 Calculate the percentage of time spent on each activity.

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  Identify the most and least efficient areas.
 Compare with industry standards or historical data.
Step 7: Compute Standard Time

Step 8: Prepare Report and Recommendations

 Summarize findings using graphs and tables.
 Suggest improvements to reduce idle time and increase efficiency.

4. Work Sampling Flowchart

Flowchart Representation
START
↓
Define Objectives
↓
Select Work Area & Activities
↓
Determine Sample Size
↓
Establish Random Observation Schedule
↓
Conduct Observations
↓
Classify & Analyze Data
↓
Compute Standard Time
↓
Generate Report & Recommendations
↓
END
(For a graphical flowchart, let me know!)

5. Case Study: Work Sampling in a Manufacturing Plant

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Background:
A car manufacturing company wants to analyze the time spent by assembly line
workers on productive and non-productive tasks.
Steps Taken:
1. Defined objective: Measure productive vs. non-productive time.
2. Selected 10 assembly line workers for the study.
3. Determined sample size using a confidence level of 95%.
4. Created a random observation schedule over 5 weeks.
5. Conducted 500 observations at different times.
6. Categorized work as Assembly (productive), Waiting for parts (idle), and
Machine Breakdown (non-productive).
7. Calculated standard time based on observations.
8. Suggested improvements, including better inventory management to
reduce waiting time.
Results:
 Productive time: 70%
 Idle time: 15%
 Non-productive time (breakdowns, waiting): 15%
 Implementing recommendations led to 10% improvement in productivity.

6. Applications of Work Sampling

1. Manufacturing Industries – Analyze machine and labor utilization.
2. Healthcare – Measure how nurses and doctors spend their time.
3. Retail – Optimize staff allocation in supermarkets.
4. Construction – Track worker efficiency on construction sites.
5. Call Centers – Determine how much time employees spend on calls vs.
idle.
6. Office Work – Improve time management for administrative staff.

7. Example Problem: Work Sampling Calculation

Problem:
A company wants to determine the proportion of time spent by workers on
productive activities. Observations were conducted randomly over two weeks, and
the data collected was:
 Productive Work – 800 observations
 Idle Time – 200 observations

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8. Advantages of Work Sampling
✔ Less Expensive – Requires fewer resources than continuous time study.
✔ Less Time-Consuming – Only requires observations at random intervals.
✔ Suitable for Indirect Work – Works well for supervisors and managerial staff.
✔ Eliminates Bias – Random observations prevent manipulation.
9. Limitations of Work Sampling
✖ Not Suitable for Short Tasks – Works best for long-duration activities.
✖ Requires Large Sample Size – To ensure statistical accuracy.
✖ Limited Control Over External Factors – Unexpected disruptions may affect
accuracy.

10. Conclusion
 Work sampling is an effective technique to measure work efficiency and
standard time.
 The design involves clear objectives, sample size calculation, random
observations, and data analysis.
 It is widely used in industries to identify inefficiencies and optimize
productivity.
 The technique provides reliable data for workforce planning and
decision-making.

1. Case Study for Mechanical Engineering Students

Work Sampling in a CNC Machine Shop
Background:
A mechanical components manufacturing unit uses CNC machines for precision
machining. The company noticed delays in production and wanted to analyze
machine and operator efficiency.
Objective:

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  Measure how much time CNC machines spend on cutting, setup, tool
change, maintenance, and idle time.
 Optimize machine utilization and reduce non-productive time.
Steps Taken:
1. Defined Study Area: Focused on a CNC shop with 5 machines.
2. Identified Activities:
o Productive Work: Cutting, drilling, turning.
o Non-productive Work: Tool change, setup, breakdown, waiting for
raw material.
3. Determined Sample Size: 500 random observations over 4 weeks.
4. Conducted Observations: Recorded CNC machine activities at scheduled
random intervals.
5. Analyzed Data:
o Productive Time: 70%
o Idle Time: 15% (Waiting for raw material, power failure)
o Non-productive Time: 15% (Setup, tool change, breakdown)
Findings & Recommendations:
 Automate tool change to reduce setup time.
 Improve raw material handling to minimize waiting time.
 Increase preventive maintenance to reduce breakdowns.
Outcome:
 Productivity improved by 12% after implementing better scheduling and
automation.

2. Case Study for IT & Computer Engineering Students

Work Sampling in a Software Development Team
Background:
A software company wants to analyze how developers spend their work hours.
The management is concerned that too much time is spent on non-coding tasks.
Objective:
 Determine the percentage of time spent on coding, debugging, meetings,
emails, documentation, and idle time.
 Optimize developer workflow.
Steps Taken:
1. Selected a team of 10 developers.
2. Categorized Activities:
o Productive: Coding, debugging, testing.
o Non-productive: Meetings, emails, documentation, waiting for
approvals.
3. Conducted Work Sampling: 800 random observations over 1 month.

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 4. Analyzed Data:
o Coding & Debugging: 55%
o Meetings & Emails: 25%
o Idle Time (Waiting for approvals): 10%
o Other (Breaks, Distractions): 10%
Findings & Recommendations:
 Introduce Agile methodologies to minimize unnecessary meetings.
 Use automated testing to reduce debugging time.
 Set clear approval workflows to reduce waiting time.
Outcome:
 Team productivity improved by 15% after reducing meeting time and
automating testing.

3. Case Study for Electrical Engineering Students

Work Sampling in an Electrical Substation
Background:
An electricity distribution company wants to analyze how technicians spend
their time at a substation.
Objective:
 Evaluate how much time is spent on maintenance, inspections, fault
repair, and idle waiting.
 Improve substation efficiency.
Steps Taken:
1. Selected a substation with 8 technicians.
2. Categorized Activities:
o Productive: Equipment maintenance, fault repair, routine inspections.
o Non-productive: Waiting for equipment, documentation, breaks.
3. Conducted 600 random observations over 6 weeks.
4. Analyzed Data:
o Maintenance & Repair: 65%
o Idle Waiting (Equipment unavailability): 15%
o Paperwork & Documentation: 10%
o Breaks & Personal Time: 10%
Findings & Recommendations:
 Improve inventory management to ensure tools and spare parts are
available.
 Implement digital documentation to reduce paperwork time.
 Introduce shift planning to balance workload better.
Outcome:

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  Fault repair efficiency improved by 20%, reducing power outage
duration.

4. Case Study for Electronics Engineering Students

Work Sampling in a PCB Manufacturing Unit
Background:
An electronics factory producing Printed Circuit Boards (PCBs) wants to
analyze production efficiency.
Objective:
 Determine the time spent on PCB assembly, soldering, quality checks,
and machine breakdowns.
Steps Taken:
1. Selected the SMT (Surface Mount Technology) assembly line.
2. Categorized Activities:
o Productive: PCB assembly, soldering, inspection.
o Non-productive: Machine breakdowns, rework, idle waiting.
3. Conducted 1000 observations over 8 weeks.
4. Analyzed Data:
o Productive Work: 75%
o Machine Downtime & Rework: 15%
o Idle Waiting (Material supply issues): 10%
Findings & Recommendations:
 Improve machine maintenance schedules to reduce breakdowns.
 Use AI-driven quality control to minimize rework.
 Ensure real-time material tracking to prevent supply chain delays.
Outcome:
 Defective PCB rate reduced by 8%, increasing overall yield.

5. Case Study for Civil Engineering Students

Work Sampling in a Road Construction Project
Background:
A construction company wants to analyze worker efficiency at a road
construction site to reduce delays.
Objective:
 Determine how much time is spent on excavation, paving, material
transportation, and idle waiting.
Steps Taken:
1. Selected a 10-km highway project.
2. Categorized Activities:
o Productive: Excavation, laying asphalt, compacting road layers.

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 o Non-productive: Waiting for materials, machine breakdowns, worker
idle time.
3. Conducted 1200 observations over 6 weeks.
4. Analyzed Data:
o Excavation & Paving: 60%
o Idle Time (Waiting for raw materials): 20%
o Machine Breakdowns & Repairs: 10%
o Other Delays: 10%
Findings & Recommendations:
 Improve material supply chain to ensure continuous work.
 Use GPS tracking to optimize transport logistics.
 Increase preventive maintenance to reduce machine downtime.
Outcome:
 Project completion time reduced by 10%, saving costs and increasing
efficiency.

Conclusion
Work sampling is applicable across all engineering disciplines to identify
inefficiencies and improve productivity.
 Mechanical Engineers – Optimize CNC machine utilization.
 IT & Computer Engineers – Improve software development efficiency.
 Electrical Engineers – Enhance power distribution and substation
operations.
 Electronics Engineers – Improve PCB manufacturing efficiency.
 Civil Engineers – Reduce delays in construction projects.
Conducting a Work Sampling Study
Introduction
Work Sampling is a statistical technique used to estimate the proportion of time
spent on various activities in a work environment. Unlike time study, which
requires continuous observation, work sampling involves random observations
over a period to determine work patterns.

Objectives of Work Sampling Study

The primary objectives of conducting a work sampling study include:
1. Determine the Utilization of Workers and Machines
o Identify the proportion of productive and non-productive time.
2. Improve Work Efficiency
o Minimize idle time and optimize workflow.
3. Reduce Costs
o Identify bottlenecks and eliminate inefficiencies.

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 4. Optimize Workforce Allocation
o Ensure labor is distributed effectively across tasks.
5. Standardize Time for Work Activities
o Establish standard time values without conducting a full-fledged time
study.
6. Identify Training Needs
o Recognize areas where workers require additional training.

Basic Steps for Conducting a Work Sampling Study

A work sampling study follows a systematic process:
Step 1: Define the Purpose of the Study
 Clearly state what is to be measured (e.g., worker productivity, machine
utilization, or process effectiveness).
 Example: A company wants to analyze how much time operators spend on
assembling vs. waiting for materials.
Step 2: Identify the Study Area and Scope
 Select departments, teams, or machines for the study.
 Determine the timeframe (e.g., one week, one month).
 Example: A CNC machine shop with 10 machines is selected for study
over four weeks.
Step 3: Define Activity Categories
 Activities are grouped into productive, non-productive, and idle
categories.
 Example:
o Productive: Cutting, drilling, assembling.
o Non-productive: Tool change, machine setup.
o Idle: Waiting for raw material, power failure.

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Step 5: Select Random Observation Times
 Observations should be conducted at random intervals throughout different
shifts.
 Use random number tables or software tools to generate observation
schedules.
Step 6: Conduct Observations and Record Data
 Observers record activity at randomly chosen moments.
 Example Observation Sheet:

Step 7: Analyze Data and Calculate Performance Ratios

 Compute the percentage of time spent in each activity.

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Step 8: Interpret Results and Make Improvements
 Identify inefficiencies and propose changes.
 Example: If idle time is 10%, implement better material handling.

Case Study: Work Sampling in an Automobile Assembly Line

Background:
An automobile manufacturer wants to study the efficiency of workers assembling
car engines.
Objective:
 Measure the proportion of time spent on assembling vs. waiting for materials
or fixing defects.
Steps Taken:
1. Defined Study Area: 20 assembly workers in Engine Assembly Line.
2. Identified Activities:
o Productive: Fitting engine parts, tightening bolts.
o Non-productive: Machine breakdowns, rework.
o Idle: Waiting for parts.
3. Conducted Observations: 1000 random observations over 6 weeks.
4. Findings:
o Productive Work: 65%
o Idle Time (Waiting for parts): 20%
o Machine Downtime: 15%
5. Recommendations:
o Improve material supply efficiency.
o Introduce preventive maintenance schedules.
Outcome:
 Productivity increased by 10% after optimizing supply chains.

Applications of Work Sampling

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 1. Manufacturing Industry: Measure machine utilization and worker
efficiency.
2. IT Industry: Analyze coding vs. non-coding activities of software
engineers.
3. Healthcare: Study the time doctors and nurses spend on patient care vs.
documentation.
4. Construction Industry: Assess productivity of construction workers.
5. Retail Sector: Determine how much time employees spend assisting
customers.
Conclusion
Work Sampling is a powerful technique that provides accurate estimates of work
efficiency without continuous monitoring. It helps in identifying productivity
bottlenecks, optimizing workflows, and reducing costs in various industries.
Establishment of Standard Time
Introduction
Standard Time is the time required to complete a task under normal working
conditions, including allowances for rest, fatigue, and delays. It is an essential
aspect of work study and industrial engineering as it helps in planning,
scheduling, and optimizing labor productivity.
Objectives of Establishing Standard Time
The key objectives of setting standard time are:
1. Workforce Planning:
o Determine the number of workers required for a task.
2. Performance Evaluation:
o Compare actual work performance with standard performance.
3. Cost Estimation & Pricing:
o Helps in determining labor costs and setting product prices.
4. Production Scheduling:
o Ensures smooth workflow and resource allocation.
5. Work Measurement & Productivity Analysis:
o Identifies bottlenecks and inefficiencies in operations.
6. Incentive Schemes:
o Establish fair wages and bonuses based on standard time calculations.
Basic Components of Standard Time
Standard time is derived from the following components:
1. Observed Time (OT):
 The actual time taken to complete a task during a work study.
 Measured using time study or work sampling.

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3. Allowances (A):
 Additional time given for fatigue, delays, and personal needs.
 Allowances include:
o Personal (P): Breaks, restroom visits (5-7%)
o Fatigue (F): Due to workload or environment (4-6%)
o Delay (D): Unavoidable machine breakdowns, waiting (2-5%)

Methods to Establish Standard Time

1. Time Study:
o Uses stopwatch technique to measure time directly.

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 o Suitable for repetitive tasks.
2. Work Sampling:
o Observes workers at random intervals to estimate time.
o Used for tasks with non-repetitive elements.
3. Predetermined Motion Time Systems (PMTS):
o Uses standard motion time data (e.g., MTM, MOST).
o Best for highly detailed job analysis.
4. Historical Data:
o Uses past records of similar tasks to set a standard time.
o Used when time study is not feasible.
Case Study: Establishing Standard Time in Different Domains
1. Mechanical Engineering: CNC Machine Operation
Problem:
A manufacturing unit wants to establish the standard time for milling a
component on a CNC machine.
Steps Taken:
1. Observed Time (OT):
o 20 samples collected using time study.
o Average OT = 8 min per component.
2. Performance Rating:
o 110% efficiency → Normal Time (NT) = 8.8 min.
3. Allowances (A):
o Personal (5%) + Fatigue (5%) + Delay (5%) = 15%
o A = 1.32 min
4. Standard Time (ST):
o ST = 8.8 + 1.32 = 10.12 min (~10 min)
Outcome:
 Machine scheduling optimized, increasing production by 10%
2. IT & Computer Science: Software Development Task
Problem:
A software company wants to set the standard time for writing and debugging
100 lines of code.
Steps Taken:
1. Observed Time (OT):
o 12 hours for 100 lines (average from 5 developers).
2. Performance Rating:
o 120% efficiency → Normal Time (NT) = 14.4 hours.
3. Allowances (A):
o Personal (3%) + Fatigue (2%) + Delay (5%) = 10% of NT

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 oA = 1.44 hours
4. Standard Time (ST):
o ST = 14.4 + 1.44 = 15.84 hours (~16 hours)
Outcome:
 Sprint planning improved, reducing delays in software release.

3. Civil Engineering: Bricklaying Work

Problem:
A construction company wants to set a standard time for laying 500 bricks.
Steps Taken:
1. Observed Time (OT):
o 4 workers → Avg. time = 5 hours.
2. Performance Rating:
o 105% efficiency → Normal Time (NT) = 5.25 hours.
3. Allowances (A):
o 15% (Fatigue + Breaks + Weather Delays)
o A = 0.79 hours
4. Standard Time (ST):
o ST = 5.25 + 0.79 = 6 hours
Outcome:
 Material supply optimized, reducing bricklayer idle time.

Applications of Standard Time

1. Manufacturing:
o Determines machine setup time, assembly line balancing.
2. Construction:
o Sets timelines for concrete mixing, bricklaying, road paving.
3. IT Industry:
o Helps in project management (Agile, Scrum) by estimating coding
and debugging time.
4. Healthcare:
o Sets standard consultation time per patient in hospitals.
5. Retail Industry:
o Helps in checkout process optimization in supermarkets.

Flowchart: Establishment of Standard Time

START
↓
Define Task & Objective
↓
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 Conduct Work Study (Time Study/Work Sampling)
↓
Record Observed Time (OT)
↓
Apply Performance Rating (PR)
↓
Calculate Normal Time (NT)
↓
Add Allowances (A)
↓
Compute Standard Time (ST)
↓
Validate with Pilot Test
↓
Implement & Monitor
↓
END

Conclusion
The establishment of standard time is crucial for efficiency, productivity, and
cost control across industries. Using proper techniques like time study, work
sampling, and PMTS, businesses can reduce inefficiencies, improve scheduling,
and set fair wages.

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