Motion Study and Chart

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Method study


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Objectives

Improvement of processes and procedures.

Improvements of factory, shop and workplace layout and ofdesign of plant and equipment.

Economy of human efforts and the reduction of unnecessary

fatigue. Improvement in the use of materials, machines and manpower.

The development of a better physical working environment.


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Selecting the work to be studied

Economic considerations

Bottlenecks

Movements of material over long distances

Operations involving repetitive work

Technical considerations

Relatively straight forward

Based on the technical knowledge of the process

Human considerations

Most difficult to foretellbecause of mental and emotionalnature.

Select an unpopular job for method study.


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Important considerations

1. Product and operation

2. Person who proposed investigation

3. Reason for proposal

4. Particulars of the job

5. Equipment

6. Layout

7. Product

8. Savings and/or increase in productivity expected.


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Why charts?

It gives a complete picture of what is being done and helps tounderstand the facts and its relationship to one another.

Details on the chart must be obtained from directobservation. Should not be from memory.

Neatness and accuracy important. Increased value if following is included:

1. Product, equipment details (code#, drawing#)

2. Job or process being carried out

3. Location and time (date) of the study4. Observers name

5. Chart reference number


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Outline process chart:

Outline process chart: The outline process chart would bear against

each symbol, an abbreviated description of what is done during the

operation or inspection.

Outline process chart which gives an overall view of the entire

process is designed to give a quick understanding of the work whichmust be done to produce a given product.

It makes possible a study of the operations and inspections so

that the best sequence may be developed. The analyst questioning

on the outline process chart may discover significant cost reductions

by combining or eliminating certain operations and inspections.

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Flow process chart-

Flow process chart-

A flow process chart is a process chart

setting out the sequence of the flow of a

product or a procedure by recording all

events under review using the appropriate

process chart symbol

Flow process chartMan type: A flow

process chart which record what the

worker does. 8


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Flow process chart- Material type:

A flow process chart which records how

material is handled or treated.

Flow process chart-Equipment type- A

flow process chart which records howequipment is used.

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Symbols of flow process chart:

OperationO

Inspection--- Transport---

Temporary storage of Delay--- D

Permanent storage--

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Multiple activity chart

A chart on which the activities of more than one subject(worker, machine, equipment) are each recorded on a commontime scale to show their interrelationship.

By using separate vertical columns, or bars to represent the

activities of different operators or machines against a commontime scale the chart shows the periods of idleness on the partof any subjects, during the process.

This makes it possible to rearrange these activities so that suchineffective time is reduced.

Extremely useful in organizing teams of operatives on mass-production work, also on maintenance work when schedulingexpensive plant.


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Facility layout / Plant lay out


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Facility layout: Method study

considerations

Important considerations: Easiest flow of material, at thelowest cost and with minimum handling.

Layout by fixed position:

E.g. Ship building, air crafts,etc.

Layout by Process or function:

Here all operations are of same nature are grouped together.

e.g. garment industry.


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Material handling


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Material handling

Typically material handing may take up to 85% of the totalprocess time.

Only important method study principle: Motion Economy!

Material handling adds to the cost of manufacture but adds

nothing to the value of the product. Therefore, ideally there should be no material handling.

Typical material handling problem solved in the same way asall method study problemstart with asking questions.

Most important question: WHY is this handling done?


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Material handling: Process

improved material handling process is traditional way of

solving any method study problems

Use of outline and process flow charts and flow diagrams to

ensure a correct workplace layout.

AIM: Minimization of movement in any planehorizontal or

vertical.

Specially critical when one is buying material handling

equipment for the workplace.

Change in workplace layout affects not only the quantity but

also the type of material handling equipment necessary.


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Material handling: Important aspects

Always try to keep material at the height at which they are tobe worked upon.

Never keep material on floor.

Always keep distances over which material is handled as short

as possible. Let gravity work for you.

Always handle in bulk over distances.

Always have sufficient boxes, platforms or container availableat the workplace.

Keep gangways clear. Dont reduce the supplementary human labor if it means

increase in the load for direct operators.


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Movement of workers


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Effects of shop layout on worker

movement

There are many activities in which workers move at irregular

intervals between a number of points in the working area, with

or without material. This happens when,

Bulk material is fed to or removed from a continuous process.

An operator is looking after two or more machines.

Laborers are delivering material to or removing work from a

series of machines.

In stores and shops when variety of materials are beingremoved from or put away into racks or bins.

In restaurants and canteens kitchens during preparation of

meal.


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String diagram

A scale plan or model on which a thread is used to trace andmeasure the path of workers, material or equipment during aspecified sequence of events.

A special form of flow diagram, in which a thread is used to

measure distance. Necessary that the string diagram be drawn correctly to scale,

whereas regular flow diagram can be drawn onlyapproximately to scale.

Start using the string diagram by recording all the relevantfacts from direct observation.

Like flow diagram, it will most often be used to supplement aflow process chart.


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String diagram

Thus, string diagram and flow chart can give clearest possible

picture of what is actually being done.

Flow process chart will be examined critically in order to

make sure that all unnecessary activities are eliminated before

a new method is proposed and tested using string diagram.

String diagram can be used to plot movements of material to

know how far the materials travel.

Most commonly, the string diagram is used for plotting the

movements of workers.


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String diagram: Process

A scale plan of working area similar to that required for a flowdiagram must be made; as stated earlier, with higher accuracy.

Machines, benches, stores etc. should be drawn to scale,together with doorways, pillars, partitions.

Completed plan should be attached to a softwood board andpins driven into it firmly at every stopping point, the headsbeing allowed to stand well clear of the surface.

Pins should also be driven in at all the turning points on theroute.

A measured length of thread is then taken and tied around thepin at the starting point of the movements.


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String diagram: Process

It is then led around the pins at the other points of call in the

order noted on the study sheet until all the movements have

been dealt with.

The result is to give a picture of the paths of movement of the

operators, those which are most frequently traversed being

covered with the greatest number of strings.

By measuring the length of the thread, the distance traveled by

the worker can be calculated.

Of two or more workers are studied over the same working

area, different colored threads may be used to distinguish

them.


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String diagram: Analysis

Examination of diagram and development of new layout donein a similar fashion as with a flow diagram.

Pins and templates are moved around until an arrangement isfound by which the same operation can be performed with a

minimum movement between them. This can be checked by leading the thread around the pins in

their new positions, keeping the same sequence.

The length of the thread for the new layout is measured andcompared with the length of thread for original layout.

Difference in length of threads represent the reduction indistance traveled as a result of improved layout.


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Travel chart

A travel chart is a tabular record for

presenting quantitative data about the

movements of workers, materials or

equipment between any number of placesover any given period of time.

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Travel chart

String diagrams take a rather long time to construct. And when

a great many movements along complex paths are involved,

the diagram looks like ugly mess of criss-crossing lines.

When the movement patterns are complex, the travel chart is

quicker and more manageable recording technique.

It is a tabular record for presenting quantitative data about

movements of workers, materials or equipment between any

number of places over any given period of time.

It is represented as a square matrix: columns indicating origin

of movement and rows the destination. Or vice versa.

Data could be travel time taken, distance traveled etc.


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Travel chart

The person conducting the study doesnt have to trace the

actual path from origin to destination.

Just the start and end of the travel is recorded as corresponding

columns and row.


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Two- handed process chart

The two handed process chart is a

process in which the activities of a

workers hands (or limbs) are recorded in

their relationship to one another.

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Micromotion study

Micromotion study: In certain types of operation, and particularly those with very

short cycles which are repeated thousands of times ( such as the packing of sweets

into boxes or food cans into cartons), it is worth while going into much greater detail

to determine where movements and efforts can be saved and to develop the best

possible pattern of movement, thus enabling the operative to perform the operation

repeatedly with a minimum of effort and fatigue. The techniques used for this purpose

frequently make use of filming, and are known collectively as micromotion study. The micromotion group of techniques is based on the ideas of dividing human activity

into divisions of movements or groups of movements (known as therblings)

according to the purpose for which they are made.

The divisions were devised by Frank B.Gilberth, the founder of motion study;

the word therblig is an anagram of his name. Gilbreth differentiated 17 fundamental

hand or hand and eye motions, to which an eighteen has subsequently been added.Each therblig has a specific color, symbol and letter for recording purposes.

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Simo Chart(Defination)

Simo Chart(Defination): A simo chart is a chart, often based on firm analysis, used

to record simultaneously on a common time scale the therbligs or groups of therbligs

performed by different parts of the body of one or more workers.

The Simultaneous motion cycle chart in short known as simo chart is the micromotion

form of the man type flow process chart. Because simo chart are used primarily for

operations of short duration, often performed with extremely rapidity, it is generallynecessary to compile them from films made of the operation which can be stopped at

any point or projected in slow motion. It will be seen that the movements are recorded

against time measured in winks (1 wink = 1/2000 minute).

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Documents

Motion Study and Chart