Manual Work & Worker-Machine

Systems
Sections:

Chapter 2  Manual Work Systems

 Worker-Machine Systems
 Automated Work Systems
 Determining Worker and Machine
Requirements
 Machine Clusters
Three Categories of Work Systems

1. Manual work system

 Worker performing one or more tasks
without the aid of powered tools
§ Worker-machine system
 Human worker operates powered
equipment
§ Automated work system
 Process performed without the direct
participation of a human worker
Manual Work System
Worker-Machine System
Automated System
 Some Definitions

Work unit – the object that is processed by the work

system
 Workpiece being machined (production work)
 Material being moved (logistics work)
 Customer in a store (service work)
 Product being designed (knowledge work)

Unit operations – tasks and processes that are

treated as being independent of other work
activities
 Manual Work Systems

Human body accomplishing some physical task

without an external source of power
 With or without hand tools
 When hand tools are used, the power to
operate them is derived from the strength of a
human worker
 Other human faculties are required, such as hand-
eye coordination and mental effort
 Pure Manual Work

Involves the physical and mental capabilities of the

human worker, and no machines, tools, or other
implements are employed in performing the task.
 Material handler moving cartons in a warehouse

 Workers loading furniture into a moving van without

the use of dollies
 Dealer at a casino table dealing cards

 Office worker filing documents

 Assembly worker snap-fitting two parts together

 Manual Work with Hand Tools
Manual tasks are commonly improved by the use of
hand tools. A tool is a device or implement for
making changes to some object (e.g., the work
unit), such as cutting, grinding, striking, squeezing,
or other process. A hand tool is a small tool that is
operated by the strength and skill of the human
user. Examples of manual tasks involving the use of
hand tools include the following:
 Machinist filing a part
 Assembly worker using screwdriver
 Painter using paintbrush to paint door trim
 QC inspector using micrometer to measure a shaft
diameter
Repetitive vs. Nonrepetitive Tasks

 Repetitive Task
 Relatively short duration (usually a few
minutes or less)
 High degree of similarity from one cycle to
the next

 Nonrepetitive Task
 Takes a long time
 Work cycles are not similar
 Cycle Time Variations
 A main objective in work design is to determine the one
best method for a task, and then to standardize its use
 Once the method has been standardized, the actual time
to perform the task is a variable because of:
 Differences in worker performance
 differences in hand and body motions
 Mistakes by worker
 Variations in starting work units
 The learning curve phenomenon
 Differences in the physical and cognitive attributes
among workers performing the task
 Variations in the methods used by different workers to
perform the task
 Worker Performance

Defined as the pace or relative speed of working

 As worker performance increases, cycle time
decreases
 From the employer’s viewpoint, it is desirable for
worker performance to be high
 What is a reasonable pace to expect from a
worker?
 Normal Performance

A pace of working that can be maintained by a

properly trained average worker throughout an
entire work shift without injurious effect on the
worker’s health or physical well-being
 The work shift is usually 8 hours, during which
periodic rest breaks are allowed
 Normal performance = 100% performance
 Common benchmark of normal performance:
 Walking at 3 miles/hr
 Normal Time

 The time to complete a task when working at

normal performance

 Actual time to perform the cycle depends on

worker performance

Tc = Tn / Pw

where Tc = cycle time, Tn = normal time, and Pw

= worker performance or pace
 Example: Normal Performance

 Given: A man walks in the early morning for health

and fitness. His usual route is 1.85 miles. A typical
time is 30 min. The benchmark of normal
performance = 3 miles/hr.

 Determine: (a) how long the route would take at

normal performance and (b) the man’s performance
when he completes the route in 30 min.
 Example: Solution

(a) At 3 miles/hr, time = 1.85 miles / 3 miles/hr

= 0.6167 hr = 37 min

(b) Rearranging equation, Pw = Tn / Tc

Pw = 37 min / 30 min = 1.233 = 123.3 %

Alternative approach in (b):

Using velocity = 1.85 miles / 0.5 hr = 3.7 miles/hr
Pw = 3.7 miles/hr / 3.0 miles/hr = 1.233 %
 Standard Performance

Same as normal performance, but acknowledges

that periodic rest breaks must be taken by the
worker

 Periodic rest breaks are allowed during the work

shift
 Federal law requires employer to pay the
worker during these breaks

 Other interruptions and delays also occur during

the shift
 PFD Allowance

To account for the delays due to:

 Personal time (P)

 Bathroom breaks, personal phone calls

 Fatigue (F)
 Rest breaks are intended to deal with fatigue

 Delays (D)
 Interruptions, equipment breakdowns
 Standard Time

Defined as the normal time but with an allowance

added in to account for losses due to personal
time, fatigue, and delays

Tstd = Tn (1 + Apfd)

where Tstd = standard time, Tn = normal time, and

Apfd = PFD allowance factor

 Also called the allowed time

 Irregular Work Elements

 Elements that are performed with a frequency of

less than once per cycle

 Examples:
 periodic changing of tools (e.g., changing a
knife blade)

 Irregular elements are prorated into the regular

cycle according to their frequency
 Example: Determining Standard
Time

 Given: The normal time to perform the regular work

cycle is 3.23 min. In addition, an irregular work
element with a normal time = 1.25 min is performed
every 5 cycles. The PFD allowance factor is 15%.

 Determine (a) the standard time and (b) the number

of work units produced during an 8-hr shift if the
worker's pace is consistent with standard
performance.
 Standard Hours and Worker
Efficiency

 Two common measures of worker productivity used in

industry to assess a worker’s productivity are standard
hours and worker efficiency
Standard hours – represents the amount of work actually
accomplished
Hstd = Q Tstd
Hstd = standard hours accomplished; Q = quantity of work
units completed; Tstd = standard time per work unit
Worker efficiency – work accomplished as a proportion of
shift hours
Ew = Hstd / Hsh
Ew = worker efficiency; Hstd = # of standard hours of work
accomplished; Hsh = # of shift hours (8 hr)
 Worker efficiency

 Worker efficiency is commonly used to evaluate

workers in industry.
 In many incentive wage payment plans, the worker’s
earnings are based on his or her efficiency or the
number of standard hours accomplished.
 Worker efficiency and standard hours are easily
computed, because the number of hours in the shift
and the standard time are known, and the number of
work units produced can be readily counted.
 Worker-Machine Systems
 When worker operates a powered equipment we
refer to the arrangement as a worker-machine
system.

 Examples:
 Machinist operating a milling machine
 Factory worker loading and unloading parts at
a machine tool.
 Truck driver driving an 18-wheel tractor-trailer
 Worker crew operating a rolling mill that
converts hot steel blocks into flat plates.
 Clerical worker entering data into a PC
 Types of Powered Equipment
Distinguished from hand tools by the fact that a source of power
other than human strength is used to operate it. Common power
sources are electric, pneumatic, hydraulic, and fossil fuel motors
§ Portable power tools are light enough in weight
 portable power drills, rotary saws, chain saws, and electric
hedge trimmers.
§ Mobile powered equipment are generally heavy pieces of
equipment
 Transportation equipment, agricultural and lawn-keeping,
forklift trucks, electric power generator at construction site
§ Stationary powered machines stand on the floor or ground
and cannot be moved while they are operating
 Machine tools (e.g., turning, drilling, milling); office
equipment (personal computers, photocopiers, telephones,
fax machines); cash registers, heat treatment furnaces
Classification of Powered
Machinery
 Numbers of Workers and Machines
Means of classifying worker-machine systems is according to
whether there are one or more workers and one or more machines

One worker and One worker & Multiple

One machine machines
 Taxicab driver and  A worker tending
taxi several production
machines
Multiple workers and Multiple workers and
One machine Multiple machines
 Ship's crew  Emergency repair
crew responding to
machine breakdowns
in a factory
 One Worker and One Machine
Good work design attempts to achieve the following
objectives:
 Design the controls of the machine to be logical and
easy to operate for the worker.
 Design the work sequence so that as much of the
worker’s task as possible can be accomplished
while the machine is operating, thereby minimizing
worker idle time.
 Minimize the idle times of both the worker and the
machine.
 Design the task and the machine to be safe for the
worker.
 Level of Operator Attention
 Full-time attention
 Welders performing arc welding
 Part-time attention during each work cycle
 Worker loading and unloading a production
machine on semi-automatic cycle
 Periodic attention with regular servicing
 Crane operator in steel mill
 Periodic attention with random servicing
 Firefighters responding to alarms
Two welders
performing arc
welding on pipe
- requires full-
time attention of
workers (photo
courtesy of
Lincoln Electric
Co.)
 Cycle Time Analysis in Worker
Machine System

In terms of cycle time analysis, worker-machine

systems fall into two categories:

(3)systems in which the machine time depends on

operator control, the task can be either repetitive or
nonrepetitive

(5)systems in which the machine time is constant and

independent of operator control, and the work cycle is
repetitive.
 Cycle Time with no Overlap between
Worker and Machine
 If there is no overlap in work elements between the worker
and the machine, then the normal time for the cycle is
simply the sum of their respective normal times:

 Normal time for cycle

Tn = Tnw + Tm

Where Tnw = normal time for the worker-controlled portion of the cycle,
min: and Tm = machine cycle time (assumed constant).

 Standard time for cycle

Tstd = Tnw (1 + Apfd) + Tm (1 + Am)

where Tnw = normal time of the worker, min; Tm = constant time for the
machine cycle, min; Am = machine allowance factor, used in the
 Worker-Machine Systems with
Internal Work Elements

 In the operation of a worker-machine system, it is

important to distinguish between the operator’s work
elements that are performed in succession with the
machine’s work elements and those that are
performed simultaneously with the machine elements.

 Operator elements that are performed sequentially

are called external work elements while those that
are performed simultaneously with the machine cycle
are called internal work elements.
Example 2.10 Internal Versus External
Work Elements in Cycle Time Analysis

 The work cycle in a worker-machine system

consists of the elements and associated times
given in the table below.

 All of the operator’s work elements are external

to the machine time.

 Can some of the worker’s elements be made

internal to the machine cycle, and if so, what is
the expected cycle time for the operation?
 Comment

 Although the total times for the worker and the machine are
the same as before, element 4 in the revised cycle (which
Consists of elements 1, 2, and 6 from the original work
cycle) is performed simultaneously with the machine time,
resulting in the following new cycle time:
Tc = 0.10 + 0.12 + 0.75 = 0.97 min
 This represents a 34% reduction in cycle time, which
translates into a 53% increase in production rate.

 When internal elements are present in the work cycle, it

must then be determined whether the machine cycle time
or the sum of the worker’s internal elements take longer.
 Automated Work Systems

Automation is the technology by which a process

or procedure is accomplished without human
assistance

 Implemented using a program of instructions

combined with a control system that executes
the instructions

 Power is required to drive the process and

operate the control system
 Levels of Automated Systems
 Semiautomated machine
 Performs a portion of the work cycle under
some form of program control
 Human worker tends the machine for the
remainder of the cycle, by loading and
unloading it
 Operator must be present every cycle

 Fully automated machine

 Operates for extended periods of time with
no human attention
Automated
robotic
spot
welding
cell (photo
courtesy of
Ford Motor
Company)