Unit Three

Work Study

Concept :

Work study is a generic term for those techniques , method study and
work measurement which are used in the examination of human work in
all its contexts.And which lead systematically to the investigation of all
the factors which affect the efficiency and economy of the situation
being reviewed , in order to effect improvement.

WORK STUDY

METHOD STUDY WORK MEASUREMENT

to simplify job and develop (TIME STUDY)
more economical method To determine the standard
of doing work time for doing an operation

HIGHER
PRODUCTIVITY

Compenets of work study

Method Study :is the systematic recording and critical examination of
existing and proposed ways of doing work ,as a means of developing and
applaying easier and more effective methods and reducing costs.
Work Measurement : is the application of techniques designed to
establish the time for a qualified worker to carry out a specified job at a
defined level of performance.

Importance of work study :

1-Work study is a means of enhancing the production efficiency
(productivity) of the firm by elimination of waste and unnecessary
operation.
2- It is the only accurate and systematic procedure oriented technique to
establish time standards.

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3- It is a technique to identify non-value adding operations by
investigation of all the factors affecting the job.
4-It is going to contribute to the profit as the savings will start
immediately and continue throughout the life of the project.
Advantage of work study:
1- It helps to achive the smooth production flow with minimum
interrruption.
2- It helps to reduce the cost of the product by eliminating waste and
unnecessary operations.
3- Better worker-management relations.
4- Meets the delivery commitment.
5- Reduction in rejections and scrap and higher utilisation of resources of
the oraganisation.
6- Helps to achieve better working conditions.
7- Better workplace layout.
8- Improve upon the existing process or methods and helps in
standardisation and simplifications.
9- Helps to establish the standard time for an operation or job which has
got application in manpower planning, production planning.

Steps involved in work study:

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 1-Select
job or process to be studied

2- Record
all the details concerning job using various recording
techniques

3- Examine
Reccorded facts critically by asking questions like
who,what,when ,why

4- Develop
Most economical method

5-Measure
The amount of work involved and set standard time
to do that job

6- Define
New method and standard time

7-Install
The new method as a standard practice

8-Maintain
New method as agreed standards

Influence of method and time study on production activities :

Influence of method and time study on production activities :
The basic objective of production management is to manufacturing the
right quantity and quality of goods at the predetermined time and pre-
established cost.Work study is tool achieve this objective. During the
product design and process design.the method of manufacture are fixed
and process planning is done using the standard times and standard
method.Methods and analysis guide with respect to how the work is to be

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best accomplished and time standards indicate how long it will take to
complete the job.
Process analysis and standard times, helps to have a control on quality
and quantity manufactured . Based upon the standard times,standard cost
are determined and this helps the analysis variance between actual and
standard costs.Product cost which is a function of method and standard
time and cost control is very much essential to be in competition.Standard
time form the basis for compensation.This helps to link wages and the
work content. Thus work -study applied in right spirit helps to accomplish
the production objectives.

Mwthods analysis show Time standards indicate how

how the work is best Manufacturing long it should take to do it.
accomplished
Production control
Engineering
Quantity and quality control Method and time study Product and design incroporate
rely on time standards methods and process planning
and process analysis

Industrial relatin Controller

Sales
Good labour relations result Standard costs are based Product cost is largely a
from equitable wages based on standard time function of manufacturing
on work content methods and measurement
control

Concept of work content:

The amount of work contained in agiven job is referred to as work
content .For a given job work content is measured in terms of man-hours
or machine-hours.
a- Basic work content: Which is the minmum time theorecically
requried to do an operation or job. This cannot be reduced. Basic
worh content will result in the following conditions:
 The design and the specification are perfect.
 Process of manufacture is exactly followed.
 No loss of working time due to any of the reasons.
Thus,the basic work content represents an ideal condition which is
not possible to achieve.

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 b- Excess work content: The actual time required completing an
operation or job is more than the basic time in preactical situations.
This additional portion of the work content is called excess work
content.
Reasons for excess work content:
a- Work content added due to defects in design or specification of a
product
Typical causes under this classification are:
 Bad desgin of the product.
 Lack of standardisation of components.
 Incorrect specifications and quality standards.
 Faulty design of components.
b- Work content added due to inefficient methods of manufacture.
 Improper selection of a manufacturing process /machine.
 Wrong of selection of tools.
 Lack of process standardisation.
 Improper layout of the shop/factory.
 Inefficient methods of material handling.
c- Ineffective time added due to shortcomings of the management
 Bad working conditions.
 Frequent production interruptions due to breakdown.
 Poor production planning and control.
 Lack of saftey measures.
 Lack of quality mindedness.
 Improper communication (lack of instructions).
 Frequent changes in set-ups (smaller to size).
 Lack of performance standards.
 Shortage of materials/tool.
d- In effective time added due to reasons attributed to work man
 Unauthorised absence from work.
 Substandard performance.
 Carelessness in working.
 Unnecessary wastage of time (Idleness).
Techniques to reduce work content
1- Management techniques to reduce work content due to product
(a) Product development.

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(b) Standardardisation (variety reduction).
(c) Value analysis.
(d) Market research/coustmer research.
2- Management techniques to reduce work content due to process
or methods
(a) Process planning.
(b) Methods study.
3- Management techniques to reduce ineffective time due to
management.
(a) Product standardisation and simplification.
(b) Product specialisation.
(c) Production planning and control.
(d) Production planning and control.
(e) Materials control.
(f) Plant maintenance.
(g) Safety measures and improved working condition.
4- Management techniques to reduce ineffective time within
controlof the workers
(a) Sound personnal policies.
(b) Operators training.
(c) Financial incentives.

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 Unit Four
Method Study
Concept
"Method study is the systematic recording and critical examination of
existting and proposed ways of doing work as a means of developing
and applying easier and more effective methods and reducing cost."
Frank B.Gilbreth is founder the method.
The method study man should have:
1- The desire and determination to produce results.
2- Ability to achieve results.
3- An understanding of the human factors involved.
OBJECTIVES OF MTHOD STUDY:
Metod study is essentially concerned with finding better ways of
doing things.It adds valueand increases the efficiency by eliminating
unnecessary operations,avoidable delays and other forms of waste.
The improvement in efficiency is achieved through:
1- Improved layout and design of workplace..
2- Improved and efficient work procedures.
3- Effective utilsation of men, machines and materials.
4- Improved design or specification of the final product.
The objectives of method study techniques are:
1- To present and analyse true facts concerning the situation.
2- To examine those facts critically.
3- To develop the best answer possible under given circumstances
based on critical examination of fact.

Scope of method study

The areas to which method study can be applied successfully in
manufacuring are:
1- To improve work methods and procedures.
2- To determine the best sequence of doing work.
3- To smoothen material flow with minimum of back tracking and to
improve layout.
4- To improve the working conditions and hence to improve labour
efficiency.
5- To reduce monotony in the work.
6- To improve plant utilsation and material utilisation.

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7- Elimination of waste and unproductive operations.
8- To reduce the manufacturing costs through reducing cycle time of
operations.

Steps involved in method study

1-Select
job or process to be studied

2- Record
all the details concerning job using various recording
techniques

3- Examine
Reccorded facts critically (purpose,place, sequence ,person
seek alternaative ,simplify ,eliminate , conbine or change)by
asking questions like who,what,when ,why

4- Develop
Most economical method

5-Measure
The amount of work involved and set standard time
to do that job

6- Define
New method and standard time

7-Install
The new method as a standard practice

8-Maintain
New method as agreed standards

The achieve the improved method method ,process ,layout and

working conditions

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1- Selection of the job for method study
Cost is the main criteria for selection of a job, process, and
department for methods analysis. To carry out the method study, a
job is selected such that the proposed method achieves one or more
of the following results:
(a) Improvement in quality with lesser scrap.
(b) Increased production through better utiliation pf resources.
(c) Elimination of unnecessary operations and movements.
(d) Improved layout leading to smooth flow of material and a
balanced production lie.
(e) Improved working conditions.

The job should be selected for the method study based upon the
following consideration:
1- Economic aspect. 2- Technical aspect 3- Human aspect
Returnee from method suggested
Rate returnee =
Cost old method

2- Recording techniques:
The next in basic procedure, after selecting the work to be studied
is to record all facts relating to the existing method. In order that
the activities selecyed for investigation may be visualised in their
entirety and in order to improve them through sebsequent critical
examination, it is essential to have some means of placing on
record all the necessary facts about the existing method.
Records are very much useful to make before and after
comparision to assess the effectiveness of the proposed improved
method.
The recording techniques are designed to simplify and
standardise the recording work.
Graphical method of recording was originated by Gilberth. In
order to make the presentation of the facts clearly, without any
ambiguity and to enable to grasp them quickly and clearly, it is
useful to use symbols instead of written description.
Method study symbols:

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 operation

inspection

transportation

Delay

storage

1- Operation
An operation occurs when an object is interntionally changed
in one or more of its characteristics (physical or chemical ). The
indicates the main steps in a process, method or procedure.
Examples of operation are :
 Turning, drilling, milling, ect.
 A chemical reaction.
 Welding, brazing and riveting.
 Lifting, loading, unloading.
 Getting instructions from supervisor.
 Taking dictation.
2- Inspection
An inspection occurs when an object is examined and compared
with standard for quality and quantity. The inspection examples
are:
 Visual obsevations for finish.
 Count of quantity of incoming material.
 Checking the dimensions.
3- Transportation
A transport indicates the movement of workers, materials or
equipment from one places another.
Ex: Movement of materials from one work ststion to another.
Workers travelling to bring tools.

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4- Delay
Delay (temporary storage)
A elay occurs when the immediate performance of the next
planned thing does not take place.
Ex: Work wating between consecutive operations.
Workers waiting at tool cribs.
Operations waiting for instructions from supervisor.

5- Storage
Storage occurs when the object is kept in an authorised custody
and is protected against unauthorised removal. For example,
materials kept in stores to be distributed to various work
centres.

Recording techiques
According to the nature of the job being studied and the purpose
for which the record is required the techniques fall into
following categories:
1- Charts.
2- Diagrams.
3- Templates.

PURPOSE
CHART:
1- Operation process chart Gives bird's-eye view of process and records
(outline process chart) principal operations and inspecting

2-Flow process chart

* Man type Sequence of activities performed by worker
* Material type Sequence of activities performed by materials.
*Equipment type Sequence of activities performed by equipment.

3-Multiple activity chart Charts activities of men and or machines on a

common time scale
4-Two handed process chart activities performed by worker's two hand.

5-Travel chart movement of materials and or men between

depertments.

6-Simo chart Activitiesof worker's hands, legs and other body

movement on common time scale
DIAGAM
7-Flow and string diagrams Path of movement of men and materials.
8-Models and templates Work place layout
9-Cycle graph and chronocycle High speed , short cycle operation recording.

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 Charts:
This is the most popular method of recording the facts. The
activities comprising the jobs are recorded using method study
symbols.A great care is to be taken in preparing the charts so that
the information it shows is easily understood and recognised. The
following information should be given in the chart:
(a) Adequate desription of the activities.
(b) Whether the charting is for present or proposed method.
(c) Specific reference to when the activities will begin and end.
(d) Time and distance scales used wherever necessary.
(e) The date of charting and the name of the person who does
charting.

1- Operation process chart

It is also called outline process chart. An operation process chart
gives the bird's-eye view of the whole process by recording only
the major activities and inspections involved in the process.
Operation process chart uses only two symbols operation and
inspection, process chart is helpful to:
 Visualise the complete sequence of operations and inspections
in the process.
 Know where the operation selected for detailed study fits into
the entire process.
 In operation process chart, the graphic representation of the
points at which materials are introduced into the process and
what operations and inspections are carried on them are shown.

Simple outline process chart

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G.1.Casting

0.1 1 inspect

0.55 1 Drill holes

face sheet

0.1 2 inspect seat

symbol Frequency time
2 1.15
0.1 3 inspect holes
4 0.4

0.6 2 M/c radius

0.1 4 radius seat

Subsidiaiary process chart

G.1.Casting

0.1 1 inspect

0.55 1 Drill holes

face sheet

0.1 2 inspect seat

symbol Frequency time
5 2.85
0.1 3 inspect holes
4 0.4

0.6 2 M/c radius

0.1 4 radius seat

the prcess 2 in common

into more from place
0.7 3 assemble 0.7
3 assemble

0.3 4 bend

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Or
G.1.Casting

0.1 1 inspect 0.7 3 Drill holes

face sheet

0.55 1 Drill holes 0.4 4 cut

face sheet

0.1 2 inspect seat 0.3 5

inspect holes

0.1 3 inspect holes 0.5 bend

6

0.6 2 M/c radius

0.2. 6 inspect holes

0.1 4 radius seat

Summary
symbol Frequency time
0.4
7 10 3.95
inspect and
center distance
7 1.3
stage change in 0.5 8 tap
size product

0.6 9 part off

new product
(size and specification)

0.2 10 inspect holes

2- Flow process chart

Flow process chart gives the sequence of flow of work of a

produce, or any part of it through the work center or the department
recording the events using appropriate symbols. It is the amplification of
the operation process chart in which operations; inspection, storage, delay
and transportation are represented. Flow process charts are of three types:

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 Material type-which shows the events that occue to the materials.

 Man type-Activities performed by the man.

 Equipment type-How equipment is used.

The flow process chart is useful

 To reduce the distance travelled by men (or materials)

 To avoid waiting time and unneccessary, delays.

 To reduce the cycle time by combining or eliminating operations.

 To fix up the sequence of operations.

 To relocate the inspection stages.

1 to officers cabon

1 take dictation

2 to his own seat

2 prepare for typing

3 types letter

1 checks for mistake

4 place in file for mistake

3 to officer's cabin

5 places file for signature

1 during checking and signature

4 back to own seat

6 type envelope

7 put letter in envelope

8 keep letter in out try

Summary
symbol
Frequency 08 01 04 - 01

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 Man type Matrerial type
chart begins: man in inspection dept chart begins: material in ggood receving
chart ends : man in inspection dept chart ends : material in stores
1 to goods receving
1 await arrival of man

1 locate component 1 to inspection dept

2 1 set on the bench

pickout component

2 to inspection dept 1 inspection

3 2 measure dimensions
set the component to bench

visual inspection 3 stamped

1
2 to stores
4 measure and record lenght
1 stored
put inspection seal
5

3 to stores

6 enter in stock

4 returen to inspection dept

Summary
Summary

symbol symbol
Frequency 06 01 04 Frequency 03 01 02 01 01

flow process chart (man and material type)

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Example (2): flow process chart

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3-Worker Machines Diagram

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4-To Hand: Example: The output device Eladio in one of the
industrial companies requires assembly (260) pieces and the work
requires moving the hand twice for each piece, represented capture
widget once and put in place the device again. Assuming it was
possible to shorten the transmission distance of the hand of the
whereabouts of the pieces into place in the assembled device limits
(6 inch) What is the required time saved.with know Note that the
actual work 250 days,

The number of hand movements to and from each piece are two
movements

Average savings if shortening the distance up to 6 inch is 0.002

minutes(60/34000=0.0016)=0.002

The amount of savings in time for each device =(260× (2×0.002)/

60)=0.017

8000×0.017=136h/day

136×250=34000h/year

he reality of a study by a professor Barneslamlah assembly screw

with metal rings in one of the industrial companies, the study
results have shown that the old way and the way amended at the
assembly as follows:

Time required to assemble the old way = 0.084

The number of times per minute assembly in the old way = 1 /

0.084 = 11.9 times

Time required to assemble the way the modified = 0.055

Number of times per minute assembly in the old way

=1/0.055=18times

Calculate the percentage increase in production First

Calculate the percentage of savings in time.

Percentage increase in production =

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 (number of pieces produced in the exact way the modified - number of
pieces produced in the exact way the old)/ number of pieces produced in
the exact way the old)=

18.2  11.9
100  53%
11.9

0.084  0.055
 100  35%
0.084

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 Unit Five

Work measurement

Concept:

The application of techniques designed ton establish the time for a

qualified worker to carry out a specified job at a defined level of
performance.

‫مجمىعح إجشاءاخ نرحذَذ انىقد ألداء انفشد انمؤهم الوجاص عمم محذد‬

Objectives of work measurement

1- Comparing of work measurement as a basic for incentives is

only a small part of its total application.

2- Assessing the correct initial manning (manpower requirement

planning)

‫ذحذَذ االحرُاجاخ انمىظمح مه انقىي انعامهح‬

3- Planning and control.

4- Realistic costing.‫ذحذَذ ذكانُف اإلوراج‬

5- Financial incentive schemes. ‫َعمم قُاط انعمم عهً إَجاد حىافض مادَح مه‬
‫خالل مضاعفح االوراج‬

6- Delivery date of goods.

7- Cost reduction and cost control.

8- Identifying substandard workers. ‫ذقُُم األداء نإلفشاد انعامهُه‬

9- Training new employees.

Techniques of work measurement

1- Repetitive work: the type of work in which the main operation

or group of operations repeat continuously during the time
spent at the job.

2- Non-repetitive work: it includes some type of maintenance and

construction work, where the work cycle itself is hardly ever
repeated identically.

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Various techniques of work measurement are:‫نماذج قياس العمل‬

1- Time study ‫دساسح انىقد‬

2- Synthesis.‫انرشكُة مه انثُاواخ انقُاسُح‬

3- Work sampling. ‫انعمم تانمعاَىح‬

4- Analytical estimating.ٍ‫انرقذَش انرحهُه‬

5- Predetermined motion and time study.‫وظم وقد انحشكح انمحذد مسثقا‬

6- Comparative estimating‫انرقذَش انمقاسن‬

7- Rated activity sampling‫ذقذَش انىشاط تانمعاَىح‬

8- Historical data.‫انثُاواخ انراسَخُح‬

Time study: A work measurement technique for recording the

times and rates of working for the elements of a specified job
carried our under specified conditions and for analyzing the
data so as to determine the time necessary for carrying out the
job at the defined level of performance.

‫ذسجُم انىقد انمطهىب الداء او اوجاص مهمح ما وتمسرىي اداء معُه مه مقثم‬
‫عامم مذسب ذذسَثا كافُا‬

Element : is a distinct part of a specified job selected for

conveniences of observation measurement and analysis.

. ‫هى رنك انجضء مه عمم معُه اخرُش نصالحُره نهمالحظح وانقُاط وانرحهُم‬

Work cycle: is a complete sequence of elements necessary to

perform a specified activity or job to yield one unit of
production.

‫ذثذأ مع تذاَح انعىصش األول فٍ انعمهُح حرً االورهاء مىه حُس ذشكم تذاَح انفرشج‬
.‫انثاوُح‬

Reasons for breaking the jobs into elements:

1- To ensure that productive time is separated from

unproductive activities‫ذحذَذ انىقد انفعال نهفعانُح اإلوراجُح‬

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2- To permit the rate of performance to be assessed more
accurately then would possible if the assessment were made
over a complete cycle. ‫ذحذَذ معذل انعمم تذقح نكم عىصش مه عىاصش‬
‫انعمهُح‬

3- To enable different types of elements to be identified and

distinguished so that element is given an appropriate
treatment.

4- To ensure element involving a high degree of fatigue to be

isolated and to make the allocation of fatigue allowance more
accurately‫ذحذَذ وسثح انسماحاخ تذقح نهعىاصش انرٍ ذحراج انً جهذ اكثش‬

5- For accuracy of rating

Types of Elements:

1-A repetitive element: is an element which occurs in every

work cycle of this job.

ٌ‫وهى رنك انعىصش انزٌ َركشس فٍ كم مشج انعىصش انركشاس‬

2-An occasional element : is one that does nor occur in every

work cycle of the job or which may occur at regular intervals.

‫انعىصش انعشضٍ وهى رنك انعىصش انزٌ َحذز خالل فرشاخ مخرهفح مه دوساخ‬
.‫انعمم قذ َحذز فٍ دوسج عمم وال َحذز فٍ دوسج اخشي مثال رل ضثظ انماكىح‬

3-A constant element :is an element for which the basic time
remains constant whenever it is performed

‫انعىصش انثاتد وهى انزٌ َرمُض تثثاخ انىقد االساسٍ خالل اجشاء دساسح انىقد‬
.‫كرىصُم انرُاس انكهشتائٍ نهماكىح‬

4-A Variable element : is an element for which the basic time

varies in relation to some basic characteristics of the product,
equipment or process.

ٍ‫ وهى رنك انعىصش انزٌ َرغُش انىقد األساسٍ نه ذثعا نهرغُش ف‬: ‫انعىصش انمرغُش‬
‫خصائص انمىرىج واِالخ او اإلتعاد مثال رل وقم انمادج األونُح حُس َرغُش انىقد‬
. ‫ترغُش انمسافح‬

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5-A manual element is an element for performed by a worker.

6-A machine element : is an element automatically performed

by a power driven machine.

‫ وهى انعىصش انزٌ ذؤدَه انماكىح أو األنح كانقطع‬: ٍ‫انعىصش اِن‬

7-Governing element : element is an element occupying a

longer time that of any other element which is being performed
concurrently.

‫وهى انعىصش انزٌ َأخز أطىل وقرا مه تاقٍ انعىاصش وانزٌ َرم‬: ‫عىصش انرىظُم‬
‫ذىفُزها تشكم مرضامه‬

8-A foreign element :is one that is observed during study but do
not form part of the given activity of the cycle.

‫ وهى انعىصش انزٌ َىرم مالحظرها خالل انذساسح ونكىها ال ذشكم‬: ٍ‫انعىصش األجىث‬
‫جضءا مه دوسج‬

Steps in time study:

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- 25 -