Method study

Method Study, Objective of method study, Pre-requisites for method study, Steps/basic procedure in method study, different method recording techniques,

1. Method Study By: - Ratnadeepsinh Jadeja

2. Method study 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.

3. The objectives of Method Study: Improvement of processes and procedures. Improvement of factory, shop and workplace layout and of the design of plant and equipment. Economy in human effort and reduction of unnecessary fatigue. Improvement in use of materials, machines and manpower. The development of better physical working environment. To find the best way of doing a job. To standardize the best method and to train workers for the same. Reduction of waste and scrap, improvement in quality. Effective material handling, greater job satisfaction, higher standards of safety and health. Improvement in the flow of production and processes.

4. Pre-requisites for method study:

5. Basic Procedure/ Steps in Method study The basic procedure for the method study: Select: the work to be studied. Record: all the relevant facts of the present or proposed method by observation or analysis. Examine: the recorded facts critically challenge everything that is done. Develop: the most practical, economical and effective method considering all the circumstances. Define: the new method so that it can always be identified. Install: that method as standard practice. Maintain: that standard practice by regular routine checks.

6. 1. Select While selecting the work for method study investigation, following factors must be considered: a) Economic consideration, b) Technical consideration c) Human reaction. Choices are: “Bottlenecks” Movement od material over long distances between shops. Operations involving a great deal of manpower and equipment. Inconsistencies in quality. Highly fatigued work. Repetitive work

7. 2. Recording Record all the activity involve in the job. For recording the various tools and techniques are used. These tools and techniques involves motion of men, material and machine Purpose of recording can be summarized as follows: To enable the process to be clearly understood. To present the existing facts for analysis. To submit the proposals to the management in a form which can be easily understood. To guide supervisors and operators regarding detailed operating instructions.

8. 3. Critical Examination Critical examination is motive force to develop a new method within the limits. It is a questioning technique having a set of questions. The governing factors can be purpose, means, sequence, place and person. All the questions can be divided into three categories: Primary questions (Deal with facts and reasons). Secondary questions (Deal with finding out alternatives) Final Questions (Deal with the implication of different alternatives and select few alternatives for development).

9. 4. Development of alternative methods and Selection of Method Based on brainstorming and examination of alternatives, several methods are selected for examination. Critically evaluation and considering various factors most economical method is select

10. 5. Implementation of new method Plan to implement new method in current method. Require necessary modification or changes of tool, devices, material, plant layout and place. Few trials are carried out in order to check new method. Check the objectives are fulfilling or not. Implement in full flange.

11. 6. Maintain a method Keep a watch whether new method is followed by workers or not. The result related to change in method should be measured in order to success of method analysis Continuous inspection of new method is required in initial period.

12. Recording Technique Charts Operation process chart Flow process chart (material type/ man type/ equipment type) Two handled process chart Multiple activity charts Travel chart Diagram Flow diagram String diagram Travel chart Motion study Micro and macro motion study Therbling Film analysis SIMO chart

13. Different process symbols Operation Inspection Transportation Delay Storage Inspection & operation Operation & transport

14. Outline Process Chart

15. Outline Process Chart

16. Flow Process Chart

17. Two- Handed Process Chart

18. Multiple Activity Chart Definition: A multiple activity chart records simultaneously the activities of all the workers and machines on a common time scale and thus shows inter relation between them. Purpose: Detect idle time being enforced on machine and workers. Optimize the work distribution between workers and machines. To decide number of workers in a group. Balance the work teams.

19. Multiple Activity Chart

20. Therbligs

21. Simo Chart (Simultaneous Motion Cycle Chart)

22. Flow Diagrams

23. String Diagrams

24. Travel Chart Movement from 1 2 3 4 5 Movement to 1 2 3 4 5

25. MICRO AND MACRO MOTION STUDY Motion study is carried out in the organization in order to improve the current working method. So, based of the improved methods fatigue of the workers can be reduced as well as overall quality of the product can be increased. When any motion study is conducted by normal human eye speed and no further detail analysis is carried using technological aids, is termed as Macro motion study. In macro motion study, analysis covers overall operations and detail analysis is not carried. In micro motion study, detailed analysis of the recorded methods of production carried out. Here, using different techniques (film analysis), detailed analysis is done and based on that the decision is taken for removing the unnecessary and wasteful movements of operator. In micro motion study, each labor activity is divided into small movements.

26. Work Place Layout Effective working area:- Is most convenient area. Normal working area:- is within the easy reach of the operator. Maximum working area:- is the area which is accessible, with full arm stretching. Maximum area should be utilized by the worker. Chair should be permitted in order to adjust the chair with working height and the person’s height.

27. Work Place Layout