METHOD STUDY1) Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs.

2) Its aim is to find best possible manufacturing procedure that requires least time and less fatigue to worker.

Used to analyze

Movement of body, people, or material

Activities of people & machines

3) Method study is a technique to reduce the work content mainly by eliminating unnecessary movements by workers, materials, or equipments.

4) However, even after that, there could be unnecessary time taken for the process because of lack of management control or inaction of worker.

>> Explanation of Method study:

Various charts to record movements

i.e. process charts,simo chart etc.

>> METHOD STUDY is a part of work study, hence to analyze method study we must know what is WORK STUDY.

WORK STUDYWork Study is a generic term for management services and system engineering techniques, used to investigate:

>> Methods of performing work (Method Study).

>> The time taken to do it (Work Measurement).

OBJECTIVES OF METHOD STUDY Improvement of processes and procedures.

Improvement in the design of plant and equipment.

Improvement of layout.

Improvement in the use of men, materials and machines.

Economy in human effort and reduction of unnecessary fatigue.

Development of better working environment.

Method Study

Work

Measurem

ents

METHOD STUDY-METHODOLOGYProcedure to accomplish method study, called "SREDIM" shall be as follow:

1. Select : The job or operation that needs improvement.

2. Record : All facts, how work is done by chart methods.

3. Examine : Every aspect of the job by asking; what, why, where, when, who and how.

4. Develop : Review ideas, eliminate, simplify, combine, re-arrange, make new method which more safe, chart new method, submit for approval.

5. Install : The new method, consider best time to introduce, convince all, train users.

6. Maintain : Check frequently, match results, correct deviations.

CHARTS IN METHOD STUDY◦ Operation Process Chart

◦ Flow process chart(man,material and machine type)

◦ Multiple activity chart

◦ Two handed process chart

◦ SIMO CHART

◦ THERBLIG-GILBRETH CHART

METHOD STUDY APPLICATIONS The need for methods analysis can come

from a number of different sources :

Changes in tools and equipment.

Changes in product design or new products.

Changes in materials or procedures

Other factors (e.g. accidents, quality problems)

RECORDING TECHNIQUES CHARTS 1. Outline process chart.

2. Flow process chart (man-type, material-type and equipment-type): This is the use of symbols and description to chart the sequence of work. The process, then, show what is happening at

different stages. The distances and time may be given.

3. Two hands process charts.

4. Multiple activity charts: This technique is used to solve problems where a number of items are dependent on each other. The aim is to reduce idle times by using the optimum number of each item. It depicts the occupied times-broken down into the number of different activities and the idle times both for the original and proposed methods of doing the job.

Diagrams and models (2-D and/or 3-D)5. Flow diagrams, which is the use of symbols for flow process

charts, superimposed on drawings and the "descriptions" are not necessary.

6. String diagrams, which is used for solving movement problems since it shows congestions and excessive distances.

7. Cut-out templates (2-D models).

8. 3-D models. Photography

>Photographs,

>Films,

>Video.

ASSEMBLY CHART1) It is an analog model of the assembly process.

2) Circles with a single link denote basic components, circles with several links denote assembly operations/subassemblies, and squares represent inspection operations.

3) The easiest method to constructing an assembly chart is to begin with the original product and to trace the product disassembly back to its basic components.

OPERATION PROCESS CHART1) The operation process chart shows the chronological sequence of all operations, inspections, time allowances, and materials used in a manufacturing or business process, from the arrival of raw material to the packaging of the finished product.

2) The chart depicts the entrance of all components and subassemblies to the main assembly.

3) Two symbols are used in constructing the operation process Chart : an operation and an inspection.

4) Operations charts show the introduction of raw materials at the top of the chart on a horizontal line.

5) Some parts require no fabrication steps. These parts are called buyouts. Buyouts are introduced above the operation

FLOW PROCESS CHART

Operation Number

Pieces / Hr

Hours / 1000

TapeCarton

A flow process chart is a chart of all the activities involved in a process.

It is similar to an operations process chart, except that more detail is shown by including transportations and delays as well as operations, inspections, and storages.

Not usually used for entire assemblies, it is used for just one component (or operator)

Add in information on:

Operation duration (time to complete)

Distance traveled (for transport operations)

Good for showing savings of a new method.

Process charts summarizes the whole process

They are used to compare the existing and the proposed methods

Process is observed, who, what, where, when, and how questions are asked

Every detail is understood and the chart of the existing situation is drawn

QUANTITY =>>

Operations: Pieces per hour

Transportation: How many are moved at a time

Inspection: How many pieces per hour if under time standard and/or frequency of inspection

Delays: How many pieces in a container

Storage: How many pieces per storage unit

Time in Hours per Unit If 250 pieces are processed in an hour then 1 unit is processed in

0.00400 hours. Record 400

If 200 units are moved in 1 minute, then 1/200 = 0.005 minutes per part, and 0.005/60 hours/part =0.00008 hrs/part. Record 8.

FLOW PROCESS TYPES : Product or Material type

Worker (Man) type

Machine type

FLOW PROCESS CHART SYMBOLS

Operation

Transportation

Inspection

Delay

Storage

EXPLAINATION OF SYMBOLS

1) Occurs when an object is intentionally changed in one or more of its characteristics

2) Usually occurs at a machine or a work station

3) Drilling, Painting, Data Entry, Cutting, Sorting, etc.

1) Occurs when an object is moved from one place to another

2) except when the movement is part of an operation or an inspection

3) Using elevator, carrying, moving with material handling devices

1) Occurs when an object is examined for identification or is compared with a standard as to quantify or quality

2) Examine the quantity or quality, read steam gauge on boiler, detect the defectives.

Operation

Transportation

Inspection

Delay

1) Occurs when the immediate performance or the next planned action does not take place

2) Work In Process inventory waiting to be processed, Employee waiting for an elevator, Waiting for accumulation of a certain quantity for packaging

1) Occurs when an object is kept under control such that its withdrawal requires authorization

2) Bulk storage of raw material, finished products inventory, archived documents

COMBINED SYMBOLTwo symbols may be combined when two activities are performed concurrently.

LEFT HAND - RIGHT HAND CHART

Storage

Operation and Inspection

Useful in analyzing the work performed by one person at one specific workstation. As the name implies, the chart follows the motion of the left and right hands of one operator .

Each hand of the worker is treated as an activity.

Each hand’s activities are broken into work elements and plotted side by side on a time scale.

Lists the work performed simultaneously by each hand

To assist in finding a better method of performing the task and

To train the operator in the preferred method.

SYMBOLS USED:

Two symbols are used in this chart:

Transportation (either an arrow or a small circle)

Action (e.g., grasp, position, use, release)

A sketch of the workplace is drawn, indicating the contents of the bins and the location of tools and materials.

Record the motions of one hand at a time

Usually necessary to redraw the chart

ABOVE FIGURE SHOWS AN EXAMPLE OF>> LEFT HAND RIGHT HAND PROCESS CHART

L-R HAND CHART FOR SIGNING A LETTER

EXAMPLE 2:

Lab # 6: Method Study

EXAMPLE 3:

EXAMPLE 4:

Lab # 6: Method Study

MAN-MACHINE CHART1) The worker and machine process chart (Man-machine chart) is used to study, analyze, and improve one workstation at a time.

2) The chart shows the exact time relationship between the working cycle of the person and operating cycle of the machine.

3) These facts can lead to utilization of both worker and machine time, and a better balance of the work cycle.

WORK-MACHINE CHART FOR COFFEE STORE

The customer, the clerk, and the coffee grinder (machine) are involved in this operation. It required 1 minute and 10 seconds for the customer to purchase a pound of coffee in this particular store. During this time the customer spent 22 seconds, or 31 percent of the time, giving the clerk his order, receiving the ground coffee, and paying the clerk for it. He was idle during the remaining 69 percent of the time. The clerk worked 49 seconds, or 70 percent of the time, and was idle 21 seconds, or 30 percent of the time. The coffee grinder was in operation 21 seconds, or 30 percent of the time, and was idle 70 percent of the time.

MULTIPLE ACTIVITY CHART

1) Also known as Gang Process Charts

2) Used when several workers operate a single machine or render a single service

3) Used when a single worker is operating several machines

4) Used to show the exact relationship between idle and operating times of both workers and machines

5) An operation performed by one member of the group may continue while another member is performing more than one operation.

6)The chart should cover the complete cycle for the longest performing member.

ACTIVITY CHART

Subject: Semi-Auto Machine

Operator MachineTime

1

2

3

4

5

6

Load machine Being loaded

Idle Run

Unload Being Unloaded

Present

THERBLIG-GILBRETH CHART1) Therbligs were suggested by "gilbreth".therbligs are used to describe the basic elements of movements or fundamental of hand motion.

2) every therblig is represented by a symbol of definite colour.

3) SIMO chart employs therbligs which are of microscopic nature where as a process chart uses symbols like operation,inspection,transportation etc. which are macroscopic nature.

PRINCIPLES OF MOTION ECONOMY1) a set of rules were designed by gilbreth in order to develop better method.

2) a better method of doing a job is one which consumes minimum time and energy by worker.

3) the various rules are high lightened below which governs the principle of motion economy-

A) RULES CONCERNING HUMAN BODY

RULES CONCERNING WORK PLACE LAYOUT AND MATERIAL HANDLING

ANALYSIS OF MOTIONThe motion or movements of limbs of a worker plays an imp. role in manufacture of products.By carefully observing a worker while he is doing a operation.,a no. of movements made by him can be identified and eliminated.

Analysis of operation when carried out in term of individual motion of a worker is known as motion analysis or motion study.

This technique highlights the use of body parts of an operator.

PHOTOGRAPHIC techniques are also used in motion study.They are as follows:

A) MICRO-MOTION STUDY1) It is carried out for a very short cycle,highly repetitive cycle.In this study a motion picture camera is used for recording motions performed by an operator.

2) The operator is filmed at 360 to 1000 frames/min. and the film is analyse frame by frame for method improvement.

3) This study is very costly.

4) A SIMO chart is used for this analysis.

B) MEMO-MOTION STUDY> It is another technique using "motion picture camera" for operation analysis.

> It suffers from micro motion study in respect to the time of filming. the camera is fitted with timing device and shoots the operation.

> This timing device permits the exposure at 60 frames /min. only.

> This study cost 6% of the cost of micro motion study.

THERBLIG-GILBRETH CHART

ABOVE FIG. SHOWS DESCRIPTION AND COLOR FOR THERBLIG-GILBRETH CHART.

SIMO (Simultaneous-Motion Cycle) Chart:“SIMO” stands for simultaneous-Motion Cycle chart. It is one of micro motion study devised by Gilbreth and it presents graphically the separable steps of each pertinent limb of the operator under study. It is an extremely detailed left and right hand operation chart.

It records simultaneously the different therbligs performed by different parts of the body of one more operators on a common time scale. The movements are recorded against time measured in “Winks” (1 wink= 1/2000 minute). These are recorded by a “Wink Counter” positioned in such a location that it can be seen rotating during filming process.

Improving the present method:

Therbligs in the SIMO chart are critically examined to explore the possibility of:

(i) Removing or eliminating the unproductive Therbligs such as find, select and avoidable delay etc.

(ii) Resequencing of the productive therbligs such as assemble and disassemble etc.

A micro motion study analysis sheet or a left hand-right chart is drawn in Fig. 4.12 for the following information’s.

Operation: Finish hand filing copper work piece.

Time for searching, lifting and holding work piece to the vice.

Table by left hand = 0.2 min

Time for opening the vice by right hand = 0.2 min

Holding the work piece in the vice with both hands = 0.4 min

Time taken for lifting and holding file by right hand = 0.2 min

Time taken for hand filing with both hands = 1.00 min

Time for bringing the micrometer by right hand = 0.2 min

Time taken in checking dimension with both hands = 0.8 min

Time for opening the vice by right hand = 0.2 min

Time taken in removing work piece with left hand = 0.2 min

Construction of “SIMO” Chart:

The SIMO chart for left hand and right hand analysis sheet inform about the degree of participation of both the hands. The time for each Therblig recorded on the analysis sheet may be shown to scale by means of a SIMO chart. Either the SIMO chart may be prepared independently or the chart may be constructed from the data available on the analysis sheet.

SIMO CHART (Corresponding to Fig. 4.12)

Department: …………………………………. Film No…………………

Operation: Finish hand filling

Charted By……………..

Date………………………………………………………………………………. Operator………………..

A SIMO chart is beneficial since it allows very accurate and detailed analysis. The work cycle form the film can be studied, easily, peacefully and away from the disturbing surroundings of the actual work station. SIMO chart is critically examined in order to grasp a picture of complete cycle in total details and assists in working out better combination of the desired motions.

For improving the methods following procedure is followed:

(i) The places in the workstation having non productive Therbligs such as search, select position and plan etc. are re-examined with a view to eliminate these basic elements as far as possible.

(ii) Attention is concentrated towards productive Therbligs like transport loaded, disassemble, assemble and use etc., which may be re-sequenced in order to reduce total cycle time and fatigue incurred to the operators.

(iii) Laws of Motion Economy help in improving the existing technique of performing an operation.

THE END