13407 1 Method Study BIS

8/7/2019 13407 1 Method Study BIS

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IS 13407 ( Part 1 ) : 1992

Indian StandardTECHNIQUES OF WORK STUDY

PART 1 METHOD STUDY

UD C 65015

0 BIS 1992

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAPAR MARG

NE W DELH I 110002October I992 Price Group 4

( Reaffirmed 2006 )


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Management and Productivity Sectional Committee, BSD 3

FOREWORDThis Indian Standard ( Part I ) was adopted by the Bureau of Indian Standards, after the draftfinalized by the Management and Productivity Sectional Committee had been approved by theBasic Standards, Systems and Services Division Council.The aim of this standard is to promote the use of method improvement procedures in all fields suchas agricultural, industrial, commercil, service activity, etc, and thereby increase productivity andquality of work life. It is essentially a practical discipline, applicable to method improvementproblems in any work activity.Work study is a &eneric term for method study and work measurement.measurement are closely linked. Method study and workductive work elements whereas work

Method study is mainly concerned with the reduction of unpro-measurement is concerned with the investigation and reductionof any infietive time and hence establishing time standards for the operation in improved manner asdetermined by method study. For the definitions of the terms work study, method study and workmeasurement, see IS 6363 : 1972 Glossary of terms in work study.

The application of method study would lead to :a) Improvement in systems and procedures;b) Improvement in processes and methods;c) Improvement in quality;d) Economy in human effort and reduction of fatigue;e) Improved layout and materials handling;f) Development of better physical working condition;g) Improvement in safety and work environment;h) Improvement in the use of resources ( man-power, materials, machine and money ); andj) Cost reduction.

In reporiing the results of a test or analysis made in accordance with this standard, if the finalvalue, observed or calculated, is to be rounded off, it shall be done in accordance with IS 2 : 1960Ku]es for rounding off numerical values ( revised ).


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IS 13407 ( Part 1 ) : 1992Indian Standard

TECHNIQUESOFWORKPART 1 METHOD STUDY

1 SCOPEThis standard (Part 1) describes the methodology andbasic techniques used in method study. It also givesvarious other techniques for informatIon collection,analysis and problem x~lviug.2 REFERENCESThe following Indian Standards arc necessary adjunctsto this standard:

IS NO. Title6363 : 1972 Cibssary of terms in work study12801 : 1989 Paretodiagramandcauseandeffectdiagra In

3 TI:RMINOI,OGYFoc the purpose this standard, the definitions given inIS 6363: 1+72 shall4 PROCEDIJHKYAl Prelin~insry

pply.

Before the application of method study to a problem,it is necessary to state :a> objrctive,b) time span,c) cost, andd) resources.

involved in carrying out the study and the likelybenefits to llow from the study.4.2 The basic steps of the method study arc :

a) Selccl,h) Record,c) ELaIIIiIIc,d) DC\ rlop,C) Dclinc.I) 11~\1;111,ndg) Maiutaiu.

STUDY

4b)c)4e)

4.2.1.1

pooruse of labour, material 0rmachiIIe capac-ity, resulting in high cost;unnecessary movcmcnt of material and highcost in work-in-process inventory;high work fatigue;frequent accidents;lackof flow of information and procrdurc de-lays;excessive overtime;higher rejections and rework; andexcessive paper work, etc.Problems identification

The following aspects maybe considered while select-ing a problem for method study :a) social,b) economic,c) technical, andd) human.

4.2.1.2 Systems approachThe objective and functions of the system or sub-system to which the problem areas form a componentpart should be kept in view while selecting a n d solvingthe problems.4.2.1.3 Prrrequi~ites of 11 trrdyHaving identified the problem for study it would benecessary to ensure that it is properly dove-tailed withthe organizational requiremerits in consultation withthe management. It will also be essential to ensure that the affectedpersons arc also involved to acceptihe need to under-take the study. This may bc followed by issuance ofproject authorization by the management.4.2.2 Record4.2.2.1 GenercllI-he fact!, rccr>rdcd should bc comprehcn~ivc and accu-rate a4 the! Iorlu ILK basis ttrr analysis nf the presentnlcthod and dcvclopmcnt of lhc proposed method.Thr collectinn of facts should bc done by directc.+scrvations, analysis ofpast recmds using the methodstudy recording techniques which mostly covcr activ-ity sequence, relationship and lime scale as given in4.2.2.2, k2.2.4, aud 4.$&3 respectively.

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IS 13407 Part 1) : 19924.2.2.2 Charts indicating sequenceCharts in this group are used to record a series of eventsor happenings in the order in which they occur butwhich do not.depict the events on time scale.

a)

b)

cl

4

Outlineprocess chrt -This is used to give anoverview of the principal operations and in-spections to indicate if more detailed studiesare required. Tbe chart records tbc main ac-tivities, namely,

0 -r- op&ations 0 - in$Ltion

Flow process chrt - This chart is used todepict activities of man, processing of materi-als/documents or use ofequipment. All eventsaffecting the operations and flow of a productor document are recorded by five processchart symbols, that is :

0 operationscl inspectionP delays

3 transportV storage

Two-handedprocess chart - This chart pxo-vides a simultaneous record of how bothhands of a worker are used. It is primarily usedfor recording a situation where the workeris working at a fixed pos.ition on repetitiveshort cycle operation like assembly. Tbe in-spection symbol is not used here, as an in-spection would usually involve delay in bandmovement.Flow process chclrt (ofice work) -- Thischart is used for recording the flow of formsand documents by setting out the sequence ofthe flow of work (office work of human ac-tivity) through the office by recording all theevents under review, using the appropriatesymbols. Additional symbols used are :

Forms W A Form : Original t2 copiesLedger/Regis+r El4.2.2.3 Charts using time sculeThese charts depict sequence of activities performedagainst a time scale. They are used 10 study the intrr-relationship between subjects (men and machines).

a) Multiple activity chart - Tbc multiple activ-ity chart reflects activities of men and/ormachines on a common time scale to show

b)

4.2.2.4

their inter-relationship. By using the numberof columns to represent the activities, thechart shows clearly periods of idleness onthe part of any of the subjects duting theprocess. A study of these charts makes itpossible to reschedule these activities so thatineffective time is reduced. Tbe chart can beused to determine the number of machineswhich the operator(s) should be able to lookafter.Simo-Chart --The simo &art is based on filmanalysis used to record simultaneously theactivities of hands, leg and other bodymovements of one or more workerqon a timescale. A video film technique may also heused.Charts using the activity relutionship

Tbesc charts show the ratb, quantum of movementof men and material on a scale plan of the workingarea.a)

h)

c)

d)

Fiowdingram-Adiagramor model substan-tially to scale, which shows the location ofspecific activities and the paths of movementof ~ICII, materials or equipment. These arcprepared by putting (be symbols of the flowprocess chart on a pIall, carb syrubol beinglocated where the activity takes place. Thearrow headc of the transport symbol sbotvsthe direction~)fmovenlcnt while the length ofIhe line joiI;ing other activity symbols indi-cakes distance moved.Sfring dicr,qrclm ---A scale plan or model o11which a thrc;tJ is used to trace and measurethe path of workers, material or equipmentduring specified sequence of event. It is veryuseful to examine work situations involvingfrequent movements. &fore a study is car-ried out, an identification code is used todefine each work, obstruction and change indirection.Travel clznrt - A tabular record for present-ing quantitative data about ~bc movements ofworkels, materials and equipment betweenany number of places over any given period oflime.Achity reltrtionship chart - A relationshipchart provides a method for identifying, dis-playing and evaluating the many relation-ships which need to be taken into account toenburc that the various functiom and servicesare physically located in the best possible rc-Iatiomhip IV racb other.l3ch fun~li~~aI activity is idrntified andtested in a row. Tbc tl~~xcnrxs required foreach activity to cvrry other activity is ralrdand reasons arc stated for any particularclosrncss rating. The vtrwrl IcIttn code isused to denote closeness rating and is markedat intersection of the concerned activities.

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4 Cycle graph - A record of movement tracedby continuotis source of light attached to amoving element on a still photograph. Thistechnique is particularly useful for highspeed short cycle operaticIns and is used toimprove the work station layouts for benchtype assemble work.0 Clrronocyck graph -A cycle graph in whichthe light source is suitably interrupled sothat the path appears as a series of pear-shaped> dots, the pointed end indicating thrdirection of movement and spacing indicatingthe speed of movement.

4.2.2.5 ModelsThese include all methods of representing actualsituation which could be manipulated andexpetimentcd in order to study the implication ofdifferent alternatives.

4 Scale models and tcmplrrr~s - These are usedto investigate layout and movement problemswhere space, position, rtcarance, etc, areimportant.b) Simrrlntion models- A simulation model is asimplified represt ntation of real life situationwhich allows the understanding of theproposed solutions of a problem to beapproached by trial and error method.C) Anctlog mud& - With these models, thesituation is studied by physical devices orprocesses whit!; behave in a similarmanner. For example, analog trial circuit whichsimulates a ventilation system.

4.2.2.6This is

Pl~otogrcrpl~yl~~id~~~ recordingused as a recording aid. This is ideal fordcpcription of work locations, new equipment andsequences. It provides a true record and covers muchmore than a written description.

4 Micro motion plrotogryl!y - A record ofdetailed movement of a single operator on atine film or video tape. By this means, thedistinct motion of the operator and theirsequence arc identified and duration ismeasured.b) Memo motion - This photography is a

IS 13407 ( Part 1) : 1992variation of micro motion in which singleframes are exposed at regular time intervals.This provides a short record of events. Analysisof the film provides information about theactivities which have taken place, their sequenceand duration.

4.2.3 ExtrmintaThis is the crucial stage of method study applicationwhen all recorded facts have to be properly siftedand arranged in terms of the physical achievements,mealls, sequence and place of achieving and theperson(s) who achieve.4.2.3.1 Criticrrl c~xuminationThe purpose of critical examination is to determinethe true reasons underlying each event and to drawup a systematic list of all possible improvements. Itrequires extensive consultation with everyone ineach position to offer useful information and also fulluse of the available technical knowledge. It is carriedout by means of two sets of questions:

a)

b)

Primary questions - The primary questionsseek to establish the need for activities. Theyform the first stage of the questioning tech-nique where the purpose, means, sequence,place and person of every activity recorded issystematically carried out and a reason foreach reply is sought. From analysis of theanswerS improvements arc made by eliminat-ing, combining, re-arranging or simplifyingthe activities. The model primary questionsarr shown in Table 1.The primary questions ensure that no as-pect of activity is missed and establish thereasons for the existing procedures.Secondury yucvtions --The secondary ques-tions seek alternatives and select thosewhich will lead to acceptable solution. Theycover the second stage of the question tech-nique during which the answers to the pri-mary questions are subjected to further queryIO determine whether possible afternatives ofplace, sequences, persons and/or means arepracticable and preferable as a means ofimprovement upon the existing method. Themodel secondary questions are shown inTable 2.

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IS 13407 ( Part 1) : 1992Table 1 P rimary Questions in Critical Examination

( Clorrse 4.2.3.1 j

PURPOSE (What is being achieved ?)Enunciate physical achievement. DO NOT mention reasons, ultimate aim or the modrtr operandi(means. person, place).

MFANS (Ilow is it being achieved ?)MATERIALS List complete details of specifications (quality, quantity, dimension, weight, COSI. etc). source of supply and

functional efficiency.

EQUIPMENT Complete spccifiealions, rapacily. serviceability, loration, etc.

SE:RVICES Dclails of sources of energy, for example. power. indusirtal gas, steam. compressed air, telephones.intercommunication, internal transport, closed TV-circuit.

METHOD Nomenclature or brief statement of the method. Details by elen~rnls in sequence of their occurrence withtimings and distances where applicable.

_ .-_.WORKING CONDITION (As P direct cwsequeare d melhod)

POSTURE Posture of working. awkward reaches, strain.HEALTH Affected through inhalation, contact. heat. cold or humidify.SAFETY From falls, weight dropping, pressures. explosion or bursts. shocks. parrties striking or collision

SEQUENCE (When is l achieved ?)AFTERBEFOREFREQUENCYOkURRENCE

Preceding key operation(s).Succeeding key operation(s).Of entire cycle of opcetion.Of the same or similar operation(s) within the cycle repetitions or duplications.

PLACE (Wbcre Is it m rcblcved 7)ILkATiONMOVEMENTSENVIRONMENT

Locality. building, rooms. hall or bry. Specificarea in room. hall or hay, dimensions of working area.All to and fro rnovennmts cwnceted with the key operation. together with distances.Illumination, ventilation. temperature. humidity. noise frtor. odour. colour. dynamics, surroundings. altitude.obstruction to movements. dust. atmospheric conditions, radiation hazards, amenities.

-_ ------_~.~PERSON (Who Rhkves il?)

DETAILS OFINDIVIDUAIS

Designation. trade, grade, category. 1ype of employment, sex. pay and physical disabilities, attitu& andaptitude. Composition of team or gang.

-1-


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IS 13407 ( Part 1 ) : 1992Table 2 Secondary Questions in Critical Examination

( C!NM.W.2.3.1)ALTERNATIVES

WHAT ELSE ?

ELIMINATE Totally.DIVERT Find subtitute for each operative word of the purp)se.AVOID the need (0 DO NOT execute the physical performance and yet accepting the necessity of its achievement.INVERT Execute the physical performance Iheotherway roundwithoutcompromisingthe ultimateaim. for example,removing finger off the ring instead of dng off the linger.MODIFY lh modificationof thequantity oLquality leading to alternative suggesting more or Less. all or better,

or higher (rr lower, etc.COMPROMISE Find all possible combinations of tt~ alternatives arrived at under modify.

_______

ELIMINATESURSTITIJTEMODIFY

COMPROMISE:COMBINEMODIFY

SUBSTITUTEPerformaoce - better quality, greater through.put.COSI - Less initial cost for new equipment, less running cost.Foigreatereconomy, less physical and mental effort, grearer safety, better quality and higher rate of rhrough-put.COMBINE Multipurpose equipment or increased utilisation.

HOW El SF>.Do without.Use somethingelse fhat ischeaperand meets the requirement or meets the requirement better but not costlirror may be costlier in case the existing one is not satisfactory or not easily procurable.In lerms of more or less etr :Quanrity - number, volume or dimensioa weight.Quality - grade or finish, tint, tone pr shade, density. temperature, pressure shape. form or finish.

functional efficiency.state - solid, liquid, gaseous or compressed.Cast - by changingqliality, quantity, stale, brand, make or source of st!pply.Possible combinaliona of alternatives under modify (for one or more malerials).Cajnposite materials or combined functions of two or more materids.In terms of more-.or less etc :Construction - sire, we igh t , simplemechaaism,easieroperation. simplemntrots, lessphysical and mental

effort. ease of installation and maintenance.

Headings for MaterhI s Apply- _-

MOMFYCOMBlNEs IMPLIFY

Prm as a whole for better quality, reducing time, increasmg through-put, saving effort and reducing cost,etc (for example, shot-blasting instead of caustic cleaning).~&II element for iecreirsing or decreasing work, efforl, time, quality and number of activities.IVarious elements.For improving quality, quantity and safety, and reducing effcui. time and cost.

Chak AlternaUves Genera ted Under MctbodIkur e Better Work hq Coudltioms

WHEN ELSE fCOMBINEREARRANGE

With preceding 01 succeeding operations.With respect to preceding or succeeding key operations. frequency and timing.

WHERE EISE ?MODIFYRELOCATE

More or less area, better environment, better layout.For reducing movementsand providing better environmen@ work place relayout.

WHO ELSE ?SUBSTlTuTEMODIFYCOMBINE

Ditferenl person(s) or art equipment.More or less number 01 peopk.Simultaneous activities; one parson for two jobs.

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IS13407(Part1):19924.2.4 DevelopmentThe purpose of this step is to develop an alternative,easier and more economic ways of achieving thedesired objectives. This is done in yollaboration withotkr experts and the line management and prefera-bly those wbo wiI1 he involved in the operations ofthe new procedures. Experiments and trials may benecessary and model.may also be used to prove andillustrate po in t s under consideration_ Specifications

will have to be drawn up to cover the equipment,materials and measurements planned to, he used invarious improved ,methods@ocedures. This ctkp bastwo physical stages :

a)b)

development of alternative methods,evaluation ofahernatives and selection of thealternative method to he implemented for shortterm and long term respectively (as given inTable 3).

Table 3 Reasons, Implkations and Notations For Development

FUts Reasons A l tmdiVCS ImpUcntiws Nobtlw for lkvebpmeatAs ioTable 1

WHYWHYWHYWHYWHY

a)b)4d)

e)

is it achieved 7tIm1 way ?

As inTable 2

then ?there ?by IhaI person ?vatid reason5 onlyultimate reasonswhy far the entiregoverning factorwhy for each operativeword or details of the factsindividuallywhy of why to at ther001 cause

a) Techalcal :

b) Ecooomic :

c) Humw

d) Soeido&al :

e) O~aniuthmal :

f) statatory :proVlSitiS

g) IlJlleconstrahtts

Desirability, feasihiiiryand practicability; Icchni-cal know-how requiredand training problems;mainlcnance, repairs andcomponent - replacementproblems; invenlory con-trol problems; quality con-trol fac4ors.Cosl of Irails; capital in-vestment in plant and ma-chinery; runningandmain-Ienati msrs; 0x1 of train-ing; loss during change-over period: rate of em-nomic regains.Physicaland mental effort;motion econoiny; heatth,safety; comfort; assimila-lion of training; motiva-tion; increased earnings;working environments;job satisfaction.Reaction and resistance tochange management andcustomer/user.Every management struc-ture assures clear defini-tion of work, authority andresponsibility. Advanta-geous changes arisingfrom r&hod study andinvestigations may be im-possible IO implemenf be-cause of demarcation bc-tween levels of authorityand responsibility.Proposals being consid-ered for further developmen;, must Ix checked toensure that they complywith statutory provisionand codes of practice.Will enable decision ondevelopmenl of shorl termplans and/or long termplans.

a) X

b) I.1

c) ST

-

-

-

alternativesnot suitablefor develop-ment.

alternalivesfound suit-able but can-not be deve-loped or im-plernenled ina short time.altcrnalivesIhatcanbede-veloped andimplementedin a shortlime.


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42.5 Other Managerial Techniques to Dwelop Solu-tions to ProblemsA few managerial techniques which can aid develop-ment ofalternative methods are given below :

-a)

cl

4

e)

Networkanalysis- A group oftechniques forpresenting information relating to time andresources so as to assist in the planning,scheduling and controlling of pmjects. Theinformation usually represented by a net-work inchdes the sequences, interdepend-en&s, inter-relationships and criticality ofvarious activities of the project.Cause and effect diagram -These diagramsmap out all the variables present in theprocess. In this diagram, the main diagonallines represent principal operations or subdi-visions of the activities. To these lines thereare other lines attached which represent sub-activities or variables. The diagram enablessystematic scrutiqy of these variables inpropr perspective. Detailed analysis and ex-perimentation will lead to important causeson which effective actions can be planned (seeIS 12801 : 1989).Decision tree (Ginzanto chart) - Decisiontree is used for applying logical thought to thechoice and evaluation of alternatives. Thebranches of each fork represent the alternativeactions available at that stage and the proba-bility. of overall success, following any con-tinuous series of branches, can be determinedand the best course of actions indicated.Decision matrix - This is a table which con-siders two or more compone+ of a strategicplan and evaluate the probable outcome ofcachpair, that is, row and column within thetable. It will provide indication of the mostadvantageous solution to the problem.Function analysis system techniques (FASTdiagram) - One of the very special tech-niques in a VE,study designed to establish theinter-relationship between various functions.a process which also helps to determine thebasic function(s), identify missing function(s)or eliminate duplicate function(s), The exer-cise results in a diagram called FAST dia-gram.

4.2.6 DefoeIS -13407 ( Part 1 ) : 1992

A corollary sage after develop is to define theproposed &hod. A&r the improved method is evolved,it should be subjected to critical examination. Whende&opment is complete, the results should be sum-marized and presented\ to management for installationof the improved method.4.2.7 InstallThe installation of an improved method is a combinedmanagement/management services function andchange over plans and schedules should be provided.The preparation is done in three parts :

a)b)4

4.2.7.1a)b)c)

Provisionofthe time table which identifies thestart and finishing dates of activities;Arrangement of the supporting services forthe new method including plant, tools, operat-ing procedures, training and wages; andTesting of the new method, if possible.Installation can be divided into three parts :change-over when the existing process is dis-mantled and replaced by the new system,operating period when supervisors and opera-101~ get to know the new system, andmodification period when any deficiency ofthe system observed and suggestions fromoperatols considered.

4.2.8 MaintainEven after an improv.ed method is installed and is op-erating satisfactorili, there may be a need to furthereffect improvement. The deviations from the newmethod can arise on account of:

a-)b)44

deliberate alterations and improvements,change as a result of suggestions made by op-erators and supervisors,operators introducing additional work ele-ments, andworkers reverting to the original me&hod.

It is essential that the work study practitioner shouldreview the job from time to time to identify discrepan-cies between the job specification and current prac-tices and to develop further improvements.


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I II Standard MarkThe use of the Standard Mark is governed by the provisions of the Bureau q/O~JiartStandards Act, 1986 and the Rules and Regtllations made thereunder. The Standard Mark onproducts covered by an Indian Standard coveys the assurance that they have been producedt.) comply with the requirements of that standard under a well defined system of inspection,testing and quality control which is devised arid supervised by RIS and operated by theproducer. Standard marked pl-oducts al-e also continusly chcckcd by 131s for conformityto that stand:lrd as a fur thcr safeguard. Details of condltlons under which a licence for theuse of the Standard Mark may bc ~I-~I~wI to manufacturers or produceIs may be obtainedfrom the Bureau of Indian Standards.


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Bureau of Indian StandardsBIS is 5~ statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goodsand attending to connected matters in the country.CopyrightBIS has the copyright of all its publications. No part of these publications may be reproduced inany form without the prior permission in writing of BIS. This does not preclude the free use, in thecourse of implementing the standard, of necessary details, such as symbols and sizes, type or gradedesignations, Enquiries relating to copyright be addressed to the Director ( Publications ). BIS.Revision of Indian StandardsIndian Standards are reviewed periodically and revised, when necessary and amendments, if any, areissued from time to time. Users of Indian Standards should ascertain that they are in possession ofthe latest amendments or edition. Comments on this Indian Standard may be sent to BIS giving thefollowing reference :Dot : No. BSD 3 ( 250)

Amendments I ssued Since Publication

Amend No. Date of Issue Text Affected

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13407 1 Method Study BIS