11

Introduction to Time and Introduction to Time and Motion StudyMotion Study

A Special Presentation for Intermarket (Pvt) Ltd, LAHOREA Special Presentation for Intermarket (Pvt) Ltd, LAHORENadeem KureshiNadeem KureshiOne Day Special Seminar on TMS – 30 Aug 2008 – Arranged by LMDA Islamabad (www.lmda.com.pk)One Day Special Seminar on TMS – 30 Aug 2008 – Arranged by LMDA Islamabad (www.lmda.com.pk)

22

Time and Motion Study: Time and Motion Study: DefinedDefined

A method created to determine A method created to determine the ‘correct time’ it takes to the ‘correct time’ it takes to complete a certain taskcomplete a certain task

A method to establish ‘the one A method to establish ‘the one best way to perform a task’best way to perform a task’

33

Time and Motion Study: Time and Motion Study: PurposesPurposes

To end ‘goofing off’ and to To end ‘goofing off’ and to establish what constituted a fair establish what constituted a fair days workdays work

To make sure that the job being To make sure that the job being evaluated does not include any evaluated does not include any unnecessary motion by the unnecessary motion by the workerworker

44

Functions of Time StudiesFunctions of Time Studies

EstablishEstablish work standardswork standards: e.g. : e.g. recommended times in which tasks recommended times in which tasks should be completed by qualified, trained should be completed by qualified, trained operators, without excessive fatigue,operators, without excessive fatigue,

SetSet expectations which are fair to both expectations which are fair to both employee and company.employee and company.

IdentifyIdentify sources of error, difficulty, sub- sources of error, difficulty, sub-optimality,optimality,

ImproveImprove an existing process, tool, or work an existing process, tool, or work environment,environment,

55

Functions of Work Functions of Work StandardsStandards Establish reasonable productivity Establish reasonable productivity

targets for experienced workers,targets for experienced workers, Provide productivity goals for Provide productivity goals for

training purposes, training purposes, Eliminate waste,Eliminate waste, Make processes more consistent,Make processes more consistent, Reduce product variability, Reduce product variability,

improve quality.improve quality.

66

Time and Motion Study: Time and Motion Study: HistoryHistory Frederick W. Taylor and his Frederick W. Taylor and his

followers developed and refined followers developed and refined the Time Studythe Time Study

Frank B. Gilbreth and his wife Frank B. Gilbreth and his wife Lillian developed and refined the Lillian developed and refined the Motion StudyMotion Study

Historically the two studies are Historically the two studies are discussed individually, today they discussed individually, today they generally are discussed as onegenerally are discussed as one

77

Time and Motion StudyTime and Motion Study

Historically: T&M Historically: T&M Studies were used Studies were used in the in the manufacturing manufacturing industry to evolve industry to evolve pay scales with the pay scales with the thought that money thought that money was the only was the only motivation for work motivation for work

88

Time and Motion StudyTime and Motion Study

Today:Today:– T&M Studies can be effective for T&M Studies can be effective for

performance evaluationsperformance evaluations– T&M Studies can be used for T&M Studies can be used for

planning purposes in order to predict planning purposes in order to predict the level of output that may be the level of output that may be achievedachieved

– T&M Studies can be used to uncover T&M Studies can be used to uncover problems and create solutionsproblems and create solutions

– T&M Studies can be used for time T&M Studies can be used for time cost analysiscost analysis

99

Time and Motion Study: Time and Motion Study: ObjectiveObjective

The objective of the Time and Motion The objective of the Time and Motion Study is to determine a ‘normal’ or Study is to determine a ‘normal’ or

average time for a job, by using average time for a job, by using observers to record exactly how much observers to record exactly how much time is being devoted to each task. time is being devoted to each task.

1010

SCOPE ENHANCEMENTSCOPE ENHANCEMENT

In 60s measurement In 60s measurement

alone found of little alone found of little

useuse

Method Improvement Method Improvement

made an integral part made an integral part

of TMSof TMS

Now called Work StudyNow called Work Study

1111

Work Measurement Divided Work Measurement Divided into Two partsinto Two parts

– Method StudyMethod Study

– Work MeasurementWork Measurement

1212

METHOD STUDYMETHOD STUDY

Systematic Recording & Critical Examination of Systematic Recording & Critical Examination of

existing and proposed processes as a means of existing and proposed processes as a means of

applying easier and effective methodsapplying easier and effective methods

1313

PDCA CyclePDCA Cycle

1414

System ThinkingSystem Thinking

Business is a network of suppliers and clients (internal and Business is a network of suppliers and clients (internal and external), which must adjust on the feedback for continuous external), which must adjust on the feedback for continuous improvement.improvement.

Process

CustomersSuppliers

Resources

Inputs Outputs

Feedback

1515

OBJECTS OF METHOD STUDYOBJECTS OF METHOD STUDY

Improvement of Processes and Procedures

Improvement of Shop-floor layout

Economy in human effort and reduction in

fatigue

Improvement in use of machines, material and

manpower

Development of better physical environment

1616

METHOD STUDY - METHOD STUDY - PROCEDUREPROCEDURE

•Select the work to be studied

•Record facts

•Examine the recorded facts

•Develop effective method

•Define the new method

•Install the new method

•Maintain the new method

1717

SELECTION OF THE WORKSELECTION OF THE WORK

Economic ConsiderationsEconomic Considerations– Will it show results in “Will it show results in “economicseconomics””– Bottlenecks/Long distance movements/Repetitive Bottlenecks/Long distance movements/Repetitive

work obvious choiceswork obvious choices

Technical ConsiderationsTechnical Considerations– Is the expected change technically feasibleIs the expected change technically feasible

Human RelationsHuman Relations– Does expected change carry possible ill feelingsDoes expected change carry possible ill feelings– How will it benefit peopleHow will it benefit people

Heavy load lifting etc obvious choicesHeavy load lifting etc obvious choices

1818

RECORDINGRECORDING

Success of whole process Success of whole process depends on recordingdepends on recording

Usual way is to write downUsual way is to write down

Charts and Diagrams used for Charts and Diagrams used for manufacturing concernsmanufacturing concerns

1919

Charts and Diagrams for Charts and Diagrams for Recording Recording

2020

EXAMINEEXAMINE

The Questioning TechniqueThe Questioning Technique

– PurposePurpose What is actually doneWhat is actually done Why is the activity necessary at allWhy is the activity necessary at all

– PlacePlace Where it is being doneWhere it is being done Why at that particular placeWhy at that particular place

– SequenceSequence When it is doneWhen it is done Why at that timeWhy at that time

2121

EXAMINEEXAMINE

The Questioning Technique contdThe Questioning Technique contd

– PersonPerson Who is doing itWho is doing it Why is he doing itWhy is he doing it

– MeansMeans How it is being doneHow it is being done Why in that wayWhy in that way

– What transportations/methods etcWhat transportations/methods etc

2222

ELIMINATION - ELIMINATION - of Non Value Added of Non Value Added activitiesactivities

SIMPLIFICATION - SIMPLIFICATION - of Complex activitiesof Complex activities

JOBBING - JOBBING - to “Better” machinesto “Better” machines

ELIMINATION - ELIMINATION - of Cross Flowof Cross Flow

EXPECTED OUTPUTS EXPECTED OUTPUTS FROM ANALYSISFROM ANALYSIS

2323

DEVELOPDEVELOP

Based on the improvement avenues Based on the improvement avenues highlighted in Examination, New highlighted in Examination, New processes are developed.processes are developed.

2424

DEFINEDEFINE

New process developed “Charted”New process developed “Charted”– Flow DiagramsFlow Diagrams– Process SheetsProcess Sheets

SOPs madeSOPs made

2525

INSTALLINSTALL

New Processes translated into New Processes translated into reality on shop floorreality on shop floor– This can involveThis can involve

Machines relocationMachines relocation Process Changes – IPI/FI to SPCProcess Changes – IPI/FI to SPC Storages besides machines redefinedStorages besides machines redefined Working conditions improvedWorking conditions improved

2626

MAINTAINMAINTAIN

The new installed processes is in The new installed processes is in a danger of reversiona danger of reversion– LegaciesLegacies– Skilled people resistSkilled people resist– New processes alien and naturally New processes alien and naturally

difficult initiallydifficult initially

2727

MAINTAINMAINTAIN

A system needs to be established A system needs to be established to ensure that the new process to ensure that the new process remainsremains

– Standardization of processesStandardization of processes– Surveys/StudiesSurveys/Studies– MonitoringMonitoring

2828

ExampleExample

2929

3030

3131

Once new process established – It Once new process established – It is measuredis measured

3232

Work MeasurementWork Measurement

3333

Work Content and Ineffective TimeWork Content and Ineffective Time

Basic work content is the irreducible Basic work content is the irreducible

minimum time theoretically required minimum time theoretically required

to produce one unit of outputto produce one unit of output

3434

Total Work Content Total Work Content

= =

Basic Work Content + Excess TimeBasic Work Content + Excess Time

3535

Excess Time Excess Time

= =

Time due to defects in design Time due to defects in design or specification of the productor specification of the product

++

Time due to inefficient Time due to inefficient methods of manufacturing or methods of manufacturing or

operation operation

3636

Ineffective TimeIneffective Time

Time for which the worker or machine or Time for which the worker or machine or

both are idle due to the shortcomings both are idle due to the shortcomings

of the management or the worker of the management or the worker

3737

Application of techniques Application of techniques

designed to establish time for designed to establish time for

qualified Worker to carry out a qualified Worker to carry out a

specified job at a defined level specified job at a defined level

of Conformanceof Conformance

Work Measurement Work Measurement

3838

Method study is concerned with Method study is concerned with

eliminating unnecessary eliminating unnecessary

movementmovement

Work measurement is concerned with Work measurement is concerned with

eliminating ineffective timeeliminating ineffective time

3939

Time Study Basic Time Study Basic EquipmentEquipment Stop watchStop watch Study boardStudy board Forms usedForms used

– Time Study SheetTime Study Sheet– TS Continuation SheetTS Continuation Sheet– Short Cycle Study SheetShort Cycle Study Sheet– Analysis SheetsAnalysis Sheets– TS Summary sheet TS Summary sheet

Digital Snap Camera Digital Snap Camera Digital Camcorder Digital Camcorder

4040

Time Study ProcedureTime Study Procedure

Select operator(s)Select operator(s) Break task down into elements (before Break task down into elements (before

you start study)you start study) Observe operators performing task: Observe operators performing task:

record time taken for each element, record time taken for each element, over several cycles.over several cycles.

Assign appropriate allowances (e.g. Assign appropriate allowances (e.g. allow time for necessary but none allow time for necessary but none productive activities, such as rest, productive activities, such as rest, cleaning eye-glasses, etc.cleaning eye-glasses, etc.

Determine appropriate work standards.Determine appropriate work standards.

4141

Selecting an OperatorSelecting an Operator

Get supervisor to help in identifying Get supervisor to help in identifying appropriate operatorsappropriate operators

Want someone qualified, trained and Want someone qualified, trained and very familiar with process (may need to very familiar with process (may need to provide training before study) if your provide training before study) if your goal is to set standards.goal is to set standards.

Prefer an average or slightly above Prefer an average or slightly above average operator.average operator.

Sometimes you have no choice of Sometimes you have no choice of operator – only one person does the job.operator – only one person does the job.

4242

Types of ElementTypes of Element Repetitive elementsRepetitive elements Occasional elementsOccasional elements Constant elementsConstant elements Variable elementsVariable elements Manual elementsManual elements Machine elementsMachine elements Governing elementsGoverning elements Foreign elementsForeign elements

4343

Timing Each ElementTiming Each Element

Cumulative TimingCumulative Timing

Flyback TimingFlyback Timing

4444

Divide Task into ElementsDivide Task into Elements

Element:Element: a group of motions that a group of motions that is relevant to the experimenter’s is relevant to the experimenter’s study objectives.study objectives.

Watch for several cycles (before Watch for several cycles (before study starts) to identify elements.study starts) to identify elements.

4545

Divide Task into ElementsDivide Task into Elements

Smallest unit that can be accurately Smallest unit that can be accurately timed is about 0.04 minutes (approx 2 timed is about 0.04 minutes (approx 2 to 3 sec).to 3 sec).

Breakpoints: use sound and sight both Breakpoints: use sound and sight both to identify breakpoints between to identify breakpoints between elements, (e.g. sound of a part elements, (e.g. sound of a part clinking in “finished” bin, sound of a clinking in “finished” bin, sound of a latch clicking shut, etc.)latch clicking shut, etc.)

4646

ExerciseExercise

TEA MAKINGTEA MAKING

4747

Tea study: GoalsTea study: Goals

To understand how long each activity took,To understand how long each activity took, To identify what “typical” processes were,To identify what “typical” processes were, To streamline processes, where possible,To streamline processes, where possible, To set work performance standards, and To set work performance standards, and

customer expectations, customer expectations, – How long should customers expect to wait for a How long should customers expect to wait for a

cup of coffee?cup of coffee?– How should performance of stores be assessed?How should performance of stores be assessed?– What performance goals should trainee’s aim What performance goals should trainee’s aim

for? for?

4848

Identifying work elementsIdentifying work elements

Many observation to identify all Many observation to identify all work elements and to come up work elements and to come up with a consistent naming.with a consistent naming.

New elements may appear,New elements may appear, Naming conventions made Naming conventions made

uniform in the analysis process.uniform in the analysis process.

4949

Data recording sheetsData recording sheets

You do not have to use the example You do not have to use the example data recording sheets in books,data recording sheets in books,

Devise what fits the task and the Devise what fits the task and the type of datatype of data

5050

Examples of Examples of Data Recording SheetsData Recording Sheets

Time and Motion Study. Site 2: Regular Machine Page

Barista: employee observations

Friday, Feb 3, 2006

T            

Op            

T            

Op            

T            

Op            

5151

““Foreign” ElementsForeign” Elements

A A foreign elementforeign element is one that does is one that does not explicitly belong in the sequencenot explicitly belong in the sequence

Examples:Examples:– Worker has to adjust glasses,Worker has to adjust glasses,– Must speak to supervisor,Must speak to supervisor,– Rest break, lunch break,Rest break, lunch break,– Wrench breaks, must find new wrench.Wrench breaks, must find new wrench.

5252

Foreign ElementsForeign Elements

Some foreign elements can be Some foreign elements can be eliminated, but others cannot or eliminated, but others cannot or should not be.should not be.

Foreign elements can give the analyst Foreign elements can give the analyst an idea of how much an idea of how much extra timeextra time is is reasonable to allow in an operation.reasonable to allow in an operation.

5353

Forms UsedForms Used

Time Study SheetTime Study Sheet

TS Continuation SheetTS Continuation Sheet

Short Cycle Study SheetShort Cycle Study Sheet

Analysis SheetsAnalysis Sheets

TS Summary sheet TS Summary sheet

5454

RATINGS & ALLOWANCESRATINGS & ALLOWANCES

On the basis of these On the basis of these measurements standard ratings measurements standard ratings and allowances are calculated. and allowances are calculated.

The standard ratings and The standard ratings and standard performance are standard performance are measured which directly tell measured which directly tell about the rate of output of the about the rate of output of the standard worker. standard worker.

5555

Rating is the assessment of the Rating is the assessment of the

workers rate of working relative to workers rate of working relative to

the redefined rate corresponding the redefined rate corresponding

to standard paceto standard pace

RATINGRATING

5656

Standard performance is the rate of Standard performance is the rate of output which qualified worker would output which qualified worker would naturally achieve without over naturally achieve without over exertion as an average over the exertion as an average over the working day or shift provided they working day or shift provided they know and adhere to the specified know and adhere to the specified method and provided they are method and provided they are motivated to apply themselves to motivated to apply themselves to their worktheir work

Standard PerformanceStandard Performance

5757

Rating PhenomenonRating Phenomenon

5858

ALLOWANCESALLOWANCES

Relaxation AllowanceRelaxation Allowance

Contingency AllowanceContingency Allowance

Special AllowancesSpecial Allowances

Policy AllowancePolicy Allowance

5959

Question:Question:

Does it make sense to estimate:Does it make sense to estimate:– AllowancesAllowances– Standard timeStandard time– Efficiency Efficiency

for a for a cashiercashier who may spend who may spend much time much time waitingwaiting for for customers to arrive?customers to arrive?

CALCULATION OF STANDARD CALCULATION OF STANDARD TIME TIME

Observed Time < Basic Time, Performance Observed Time < Basic Time, Performance is above the standard and vice versa.is above the standard and vice versa.

BT = OT + BT = OT + OT X (R – 100)OT X (R – 100) 100100 If R = 120,If R = 120, OT = 30, then BT = 30 + [600/100 =] 6 = OT = 30, then BT = 30 + [600/100 =] 6 = 3636

Then observed time is 6 minutes less than Then observed time is 6 minutes less than basic time.basic time.

CALCULATION OF STANDARD TIME CALCULATION OF STANDARD TIME

aa OTOT b RF c RA db RF c RA dCA e CA e

Observed Time R

Standard Time

W D

Work ContentBasic Time

6262

Few foreseeable problemsFew foreseeable problems

They may resent the study considering it is being They may resent the study considering it is being

used to determine the pay scaleused to determine the pay scale Workers may change the rate at which they workWorkers may change the rate at which they work Pressure may increase mistakes madePressure may increase mistakes made Workers may alter normal work methods to Workers may alter normal work methods to

disrupt the studydisrupt the study

Thank YouThank You