Time and Motion Study & Work Measurementsite.iugaza.edu.ps/aschokry/files/2010/02/Dr.-Abed-Schokry-IE-HF...Time and Motion Study & Work Measurement ... Conduct a job analysis of the

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Islamic University of Gaza - Palestine

Department of Industrial Engineering


Time and Motion Study & Work Measurement

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Definitions

• Motion study or work methods design:for finding the preferred method of doing work. That is, the ideal method or one nearest to it.

• Time study or work measurement: for determining the standard time to perform a specific task.


• The fundamental tools that result in increased productivity are:

methods, time study standards, and work design.

• All aspects of a business or industry - sales, finance, production, engineering, cost, maintenance, and management – provide areas for the application of methods, standards, and work design.

Time and Motion Study & Work Measurement




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• Also, they are creative in improving existing methods and products to help the company attain leadership in its product line. In this activity, good labor relations may be maintained through establishing fair labor standards.

• Methods, standards, and work design and measurement offer real challenges.

• Industries with competent engineers, business administrators, industrial relations personnel, specially trained supervisors, and psychologists all using methods, standards, and work design techniques are certainly better able to meet competition and better equipped to operate profitably.

Time and Motion Study & Work Measurement (cont.)


• If the production department is considered the heart of an industrial enterprise, the methods, standards, and work design activity is the heart of the production group.

• They use initiative and creativity to develop efficient tooling, worker and machine relationships, and workstations on new jobs in advance of production.

• Also, they are creative in improving existing methods and products to help the company attain leadership in its product line. In this activity, good labor relations may be maintained through establishing fair labor standards.





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• The objective of the manufacturing manager is to produce a quality product, on schedule, at the lowest possible cost,

with a minimum of capital investment and a maximum of employee satisfaction.

• The focus of the reliability and quality control manager is to maintain engineering specifications and satisfy customers with the product’s quality level and reliability over its expected life.

• The production control manager is principally interested in establishing and maintaining production schedules.



• The manager of methods, standards, and work design is mostly concerned with combining the lowest possible production cost with maximum employee satisfaction without sacrificing workplace safety.

• The maintenance manager is primarily concerned with minimizing facility downtime due to unscheduled breakdowns and repairs.

• Figure illustrates the relationship of the manager of the methods, standards, and work design department to the staff and line departments under the general manager.





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Methods engineers use a systematic procedure to develop a work center, produce a product, or provide a service.

Select the project. Typically, the projects selected represent either new products or existing products that have a high cost of manufacture and a low profit, experiencing difficulties in maintaining quality and are having problems meeting competition are projects for methods engineering.

Get and present the data. Assemble all the important facts relating to the product or service. These include drawings and specifications, quantity requirements, delivery requirements.

Methods engineers


Analyze the dataUtilize the primary approaches to operations analysis to decide

which alternative will result in the best product or service. These primary approaches include: purpose of operation, design of part, tolerances and specifications, materials, process of manufacture, setup and tools, working conditions, material handling, plant layout, and work design.

Develop the ideal methodSelect the best procedure for each operation, inspection, and

transportation by considering various constraints associated with each alternative, including productivity, ergonomics, and health and safety implications.

Methods engineers (Cont.)




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Present and install the methodExplain the proposed method in detail to those responsible for

its operation and maintenance. Consider all details of the work center, to insure that the proposed method will provide the results anticipated.

Develop a job analysisConduct a job analysis of the installed method to insure that

the operators are adequately selected, trained, and rewarded.

Establish time standardsEstablish a fair and equitable standard for the installed

method.



Follow up the methods.

At regular intervals, audit the installed method to determine if the anticipated productivity and quality are being realized, whether costs were correctly projected, and whether further improvements can be made.

WORK DESIGN

• As part of developing or maintaining the new method, the principles of work design must be used to fit the task and workstation ergonomically to the human operator.





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Standards are the end result of time study or work measurement. This technique establishes a time standard allowed to perform a given task, based on measurements of the work content ( that is time taken to manufacture the product or to perform the operation if the design or specification of product or service provided were perfect) of the prescribed method, with due consideration for fatigue and for personal and unavoidable delays.

• Time study analysts use several techniques to establish a standard: a stopwatch time study, computerized data collection, standard data, predetermined time systems, work sampling, and estimates based on historical data.

STANDARDS


• Time study analysts use several techniques to establish a standard: a stopwatch time study, computerized data collection, standard data, predetermined time systems, work sampling, and estimates based on historical data.

• The resulting standards are used to implement a wage payment scheme. In many companies, particularly in smaller enterprises, the wage payment activity is performed by the same group responsible for the methods and standards work.

• Production control, plant layout, purchasing, cost accounting and control, and process and product design are additional areas closely related to both the methods and standards functions.

STANDARDS




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The principal objectives of methods, standards, and work design are:

(a) Increase productivity and product reliability safely (b) to and to decrease unit cost

HISTORICAL DEVELOPMENTS

FREDERICK W. TAYLOR

Frederick W. Taylor is known as the father of scientific management and industrial engineering.

OBJECTIVES OF METHODS, STANDARDS, AND WORK DESIGN


• He is the first person to use a stopwatch to study work content. Many years later, he established his four Principles of Scientific Management:

1. Develop a science for each element of a person’s work.

2. Select the best worker for each task and train that worker in the prescribed method.

3. Develop a spirit of cooperation between management and labor in carrying out the prescribed methods.

4. Divide the work into almost equal shares between management and labor, each doing what they do best.

FREDERICK W. TAYLOR (Historical Review)




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F.W. Taylor and Scientific Management

• Scientific Management– The systematic study of the relationships between people

and tasks for the purpose of redesigning the work process for higher efficiency.• Defined by Frederick Taylor in the late 1800’s to replace

informal rule of thumb knowledge.• Taylor sought to reduce the time a worker spent on each

task by optimizing the way the task was done.


Frank and Lillian Gilbreth

• Refined Taylor’s work and made many improvements to the methodologies of time and motion studies.– Time and motion studies

• Breaking up each job action into its components.• Finding better ways to perform the action.• Reorganizing each job action to be more efficient.

• Also studied worker-related fatigue problems caused by lighting, heating, and the design of tools and machines.




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• Frank and Lillian Gilbreth were the founders of the modern motion study technique, which may be defined as the study of the body motions used in performing an operation, to improve the operation by eliminating unnecessary motions, simplifying necessary motions, and then establishing the most favorable motion sequence for maximum efficiency.

• They developed theories of efficient motions through defining terminology of the entire range of manual motions. These 17 elementary subdivisions of motion, later engineers named a short word, therblig.

FRANK AND LILLIAN GILBRETH (Historical Review)


• Henry Laurence Gantt invented the task and bonus system or earned-hour plan. Rather than penalizing the less proficient worker as Taylor did with his multiple piecework plans, Gantt advocated a livable wage with a sizable bonus for performance over 100%.

• While Taylor emphasized the analytical and organizational aspects of work, Gantt was more interested in operator selection, training, and motivation.

HENRY LAURENCE GANTT (Historical Review)




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• Dr. Barnes was one of the first and best-known professors of engineering in the field of work measurement. His achievements included writing the longest published text on work measurement, a thorough description of the Gilbreths’ micro-motion study, time study, and the procedure for work sampling.

• He conducted numerous methods studies of activities with motion picture cameras and developed rating films for training time study technologists.

RALPH M. BARNES (Historical Review)


Four Principles of Scientific Management

• Principles to increase efficiency:1. Study the ways jobs are performed now and determine new

ways to do them.• Gather detailed time and motion information.• Try different methods to see which is best.

2. Codify the new methods into rules.• Teach to all workers the new method.

3. Select workers whose skills match the rules.

4. Establish fair levels of performance and pay a premium for higher performance.• Workers should benefit from higher output




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Problems with Scientific Management

• Managers frequently implemented only the increased output side of Taylor’s plan.– Workers did not share in the increased output.

• Specialized jobs became very boring, dull.– Workers ended up distrusting the Scientific Management

method.• Workers could purposely “under-perform.”

– Management responded with increased use of machines and conveyors belts.


• Technical organizations have contributed much toward bringing the science of time study, work design, and methods engineering up to present-day standards.

• The Institute of Industrial Engineers (IIE) was founded in 1948 with the purposes of:

– maintaining the practice of industrial engineering on a professional level;

– fostering a high degree of integrity among the members of the industrial engineering profession;

ORGANIZATIONS




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– encouraging and assisting education and research in areas of interest to industrial engineers;

– promoting the interchange of ideas and in formation among members of the industrial engineering profession (e.g., publishing the journal IIE Transactions);

• In the area of work design, the first professional organization, the Ergonomics Research Society, was founded in the United Kingdom in 1949. It started the first professional journal, Ergonomics, in 1957.

• Currently, there are well over 5,000 members organized in 20 different technical groups.

ORGANIZATIONS (cont. )


• Practitioners of methods, standards, and work design have come to realize that such factors as age, health and well-being, physical size and strength, training attitudes, job satisfaction, and motivation response have a direct bearing on productivity.

• Today’s practitioners must use the “humane” approach. They must be well versed in the study of human behavior and accomplished in the art of communication. They must also be good listeners, respecting the ideas and thinking of others, particularly the worker at the bench.

PRESENT TRENDS




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• Today, there is a greater intrusion by the government in the regulation of methods, standards, and work design. For example, military equipment contractors and subcontractors are under increased pressure to document direct labor standards as a result of MIL-STD 1567A

• Similarly, in the area of work design, Congress passed the OSH Act establishing the National Institute for Occupational Safety and Health (NIOSH), are search agency for developing guidelines and standards for worker health and safety, and the Occupational Safety and Health Administration (OSHA) an enforcement agency to maintain these standards.

PRESENT TRENDS


Operation Analysis Approach-2

• Set-up and Tools– Reduce set-up time: SMED

• Material Handling– Handling equipment– Ergonomic principles

• Lay-out




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Operation Analysis Approach-1

• Method analysis– Eliminate, simplify, or combine operations

• Design analysis– Reduce the number of parts– Design for manufacturability and assembly

• Manufacture sequence– Rearranging operations– Mechanizing manual operation





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The Four Principles of Motion Economy

1. Reduce the Number of Motions– Eliminate or reduce the number of motions

2. Perform Motions Simultaneously

q Design improvements in the methods and tools which allow both hands to be used at the same time


The Four Principles (cont’d)

3. Shorten Motion Distances – Reduce - walking, reaching, stretching, squatting and

turning, etc.

4. Make Motion Easierq Work should be smooth and rhythmical, reduce fatigue and

promote safety




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Use of the Human Body

• Both hands should start and finish the operation at the same time.

• Reduce idle time for either or both hands• Arm motions should be symmetrical• Employ curved movements during the operation• Employ rhythmical standard operation• Ensure a similar focal point for tools, materials, etc.


Arrangement of the Work Place

• Use fixed positions for tooling and parts to allow habits to form easily

• Use gravity feeding to ensure a common pickup point• Position parts, materials and tools to enable sequential

use• Use ejector systems or drop deliveries, so the operator

has minimal effort to pass on parts to the next operation• Benches and chairs should be at the correct working

height to avoid interrupted motions• All equipment should be within the maximum work area




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Design of Tools and Equipment

• Eliminate the need to use one hand purely to hold a part • Use combination tools• Use counterbalances on heavy tooling• Ensure handles on tools are designed to use maximum

hand contact• Place tooling in the most convenient positions• Separate part supplies should be used for two operators.• Tools should be placed to enable immediate use• Provide chutes for access of parts, and components

in/out of the workplace


5 S

• Seiri, Seiton, Seiso, Seiketsu, Shitsuke

• Sort, Clean, Set in order, Standardize, Progress




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Poka Yoke

• “Mistake proofing”• A manufacturing technique of preventing errors by

designing the manufacturing process, equipment, and tools so that an operation literally cannot performed incorrectly


Excuses…

• I like the way I am doing it now. • It's too radical a change. • I tried it once and didn't like it. • It sounds like a production line. • It won't work in our office. • I think we should look into it further before we act. • It won't pay for itself. • I know a fellow who tried it. • We've always done it this way.




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Principles of Motion Economy

• Both hands should work at the same time.• The hands should work in opposite symmetrical

directions.• Each hand should go through as few motions as

possible.• The work place should be designed to avoid long

reaches.• Avoid using the hand as a holding device.


Work Measurement Basics

• Objective:– Labor Standards/Time Standards

• Time per Cycle of a Job• Timing:

– Comes after methods analysis/motion study• Focus:

– Proper Method– Average Pace– Average Worker




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Work Measurement Uses

• Estimating Work Force/Capacity Requirements• Costing Production Operations• Worker Performance/Wage Incentive Systems• Scheduling Production


Work Measurement Techniques

• Stopwatch Time Study– Compiled from Observations

• Historical Experience– Rough Estimates-Tables/ Formulas

• Work Sampling– Statistical Estimate-Percentage of Occurrence

• Predetermined Time Standards– Commercial Systems– Standard Tasks/Movements




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Work Measurement

• Motion study is the systematic study of the human motions used to perform an operation.

• Work measurement: Measures time requirement to make a product• Time standards: The time required for a trained worker to perform

a given task using a prescribed work method with normal effort and skill.

• Uses of standards

Uses of standards %Estimating and cost 89%Incentive compensation plans 59Production scheduling 55Performance appraisal 41Staffing & capacity plans 2


Major Methods of Work Measurement

Type of Task Major MethodsVery short interval, highlyrepetitive

Film analysis

Short interval, repetitive Stop watch time study orpredetermined data

Task in conjunction withmachinery or other fixedprocessing time equipment

Elemental data or subjectiveestimate

Infrequent work or work of a longcycle time

Work sampling or subjectiveestimate




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The Critics of Work Measurement

• UPS has 1000 industrial engineers (out of a work force of 152,000) set standards for a myriad of closely supervised tasks. Productivity and profits are high.

• “Time study is a dark-ages technique, and it’s dehumanizing to track someone around with a stopwatch.”

Vice President, H.B. Maynard & Co.


Time Study Sheet




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Elemental Standard Time Data

• Develop tables of performance times for operations that are common to many applications.

• Avoids the need for separate time studies.


Motion Study

• Motion study - systematic study of human motions used to perform operations

• Micro approach, one worker in workstation

.




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• Motion study principles - guidelines for motion-efficient work

• Analysis of therbligs - breaking job into elemental motions • Micromotion study - use of motion pictures and slow

motion to study minute motions• Charts• Done before work measurement

• Motion study - systematic study of human motions used to perform operations,

• Micro approach, one worker in workstation

Motion study & Motion Study Techniques


Predetermined Motion-Time Data Systems• Uses historically developed data for time required for

basic body movement, elements of operation, or even an entire operation.

• Very useful in estimating new product cost.• Procedure

– Divide total task into elements.– Rate the difficulty of each element.– Look up tables for the time allowed for each element.– Add all element times together.

• Systems available– Methods time measurements (MTM).– Basic motion time study (BMT).– Motion time survey (GE).– Work factor.




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The MTM Predetermined Motion-Time Data System




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Time and Motion Study & Work Measurementsite.iugaza.edu.ps/aschokry/files/2010/02/Dr.-Abed-Schokry-IE-HF...Time and Motion Study & Work Measurement ... Conduct a job analysis of the