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WELCOME TO THE COURSE WORK STUDY (IE 341)

WELCOME TO THE COURSE WORK STUDY (IE 341). OFFERED BY SAYED ALIUL HASAN RIZVI, PhD PROFESSOR DEPT OF INDUSTRIAL ENGINEERING KING ABDULAZIZ UNIVERSITY, JEDDAH. INTRODUCTION.

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WELCOME TO THE COURSE WORK STUDY (IE 341)

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  1. WELCOME TO THECOURSEWORK STUDY(IE 341) OFFERED BY SAYED ALIUL HASAN RIZVI, PhDPROFESSOR DEPT OF INDUSTRIALENGINEERING KING ABDULAZIZ UNIVERSITY, JEDDAH

  2. INTRODUCTION • With increasing complexities of the technological world,need to simplify the work system has been increasing day by day. • Work study is an area of knowledge that addresses the problem of work simplification with the basic objectives of • PRODUCTIVITY ENHANCEMENT, and • HUMAN COMFORT & SAFETY

  3. “WORK STYDY” HAS MANY OTHER NAMES FOR EXAMPLE METHODS ENGINEERING, WORK SCIENCE, WORK DESIGN, JOB ESIGN WORK METHODS DESIGN &WORK MEASUREMENT MOTION &TIME STUDY Original names were: Motion study,Time Study & then, Motion & Time Study

  4. DEFINITION It is the systematic study of work systems with the purposes of • Developing the preferred system and Method ( with lowest cost) 2. Standardizing this system and method 3. Determining standard time for the task 4. Assisting in training the worker in the preferred Method

  5. EXPLANATION Above stated definition has FOUR parts. However, the TWO most important for WORK STUDY are: 1.MOTION STUDY (or Work Methods Design) & 2. TIME STUDY (or Work Measurement)

  6. ILO DEFINITION It is the systematic examination of carrying on activities so as to improve the effective use of resources and to set standards of performance for the activities being carried out.

  7. LECTURE : 3-4CHAPTER : 2WORK STUDY & PRODUCTIVITY

  8. HUMAN’S BASIC NEEDS & PRODUCTIVITY In 1950: world population was 2.5 b Now : it is of the order of 6.5 b 90% increase has occurred in developing nations.

  9. CONTD. Out of these people, more than 1 b arebelow poverty line, struggling for the BASIC NEEDS which are : • food, • clothing, • shelter, • security, • health and • essentials like water, sanitation etc.

  10. CONTD. For Improving the STANDARD OF LIVING, of its citizens, the concerned nation must raise its PRODUCTIVITY for economic growth. For any organization, its input-output system can be represented as follows: INPUT OUTPUT PROCESS

  11. CONTD. INPUTSmay be in the form of different M’s: man, material, machine, method, management, market, message ( i.e. information), moment (i.e. time ) OUTPUTmay be a product or service. PRODUCTIVITY may be defined as follows:

  12. MATHEMATICALLY:PRODUCTIVITY = [OUTPUT / INPUT]THUS:PRODUCTIVITY measures the extent to which a certain OUTPUT can be extracted FROM A GIVEN INPUT.It may be noted that PRODUCTION ( which is number of products) is different from PRODUCTIVITY.

  13. CONTD. • WORK STUDY IS A TOOL OF PRODUCTIVITY ENHANCEMENT. • It simplifies a job TO REDUCE UNNECESSARY OR EXCESS WORK,WASTEFUL USE OF RESOURCESand sets up STANDARD TIME for performing that job.

  14. CONTD. THIS IMPLIES THAT : • THERE IS A DIRECT RELATIONSHIP BETWEEN WORK STUDY AND PRODUCTIVITY. • THUS, BY APPLYING WS PRINCIPLES IF THE COST IS REDUCED BY 20%, THEN, WE CAN SAY THAT PRODUCTIVITY HAS GONE UP BY 20%.

  15. WORK CONTENT OF A JOB “WORK CONTENT” • It means the amount of work contained in a given job/work/product/process. • It is measured inMAN-HOURS/ WORK-HOURS (effort or labor of ONE person for ONE hour), or MACHINE HOURS (running of a machine/plant for ONE hour).

  16. TOTAL TIME OF A JOB ‘TOTAL TIME OFA JOB’ COMPRISES OF: 1. BASIC WORK CONTENT & 2. EXCESS WORK CONTENT BASIC WORK CONTENT is irreducible minimum time required theoretically to produce one unit of productIn REAL LIFE WORLD, actual operation times are FAR MORE IN EXCESS due to the EXCESS WORK CONTENT.

  17. CONTD. • EXCESS WORK CONTENT may be due to following THREE CATEGORIES of factors: (i) A-category: A1: POOR DESIGN & FREQUENT DESIGN CHANGESA2: WASTE OF MATERIALSA3: INAPPROPRIATE QUALITY STANDARDS

  18. CONTD. (ii) B-category B1: POOR LAYOUT & POOR UTILISATION OF SPACEB2: INADEQUATE MATERIAL HANDLINGB3: FREQUENT STOPPAGES AS PRODUCTION CHANGES FROM ONE PRODUCT TO ANOTHER

  19. CONTD. B4: INEFFECTIVE METHOD OF WORK B5: POOR PLANNING OF INVENTORY B6: FREQUENT BREAKDOWN OF MACHINES AND EQUIPMENT

  20. iii) C-categoryC1: ABSENTEEISM AND LATENESSC2: POOR WORKMANSHIP, ANDC3: ACCIDENTS AND OCCUPATIONAL HAZARDS TOTAL TIME OF A JOB = BASIC WORK CONTENT + EXCESS WORK CONTENT ( A + B +C ) (OR, TOTAL INEFFECTIVE TIME)

  21. LECTURE : 5-8 CHAPTER : 3 WORK STUDY ,THE APPROACH:

  22. WS IS VALUABLE because By carrying out its systematic procedures,one can get results as good as or even better than the less systematic genius would have been able to achieve in the past.It is systematic both in the investigation of the problem and in the development of its solution.

  23. CONTD. • It raises productivity of the plant /unit by simply reorganization of the work, with either a nominal or no extra input.It sets the performance standards on which the effectiveness of the production planning and control depends.

  24. CONTD.It contributes to human safety by providing safer methods of work, and allows for better working conditions by exposing the hazardous situations.Its application starts providing savings immediately, and continues till the operation continues.

  25. CONTD. It is a tool that can be used every where, be it industrial or non-industrial environment. It is easy and relatively cheaper in its application.It is an excellent weapon for starting an attack on the inefficient system. • HOWEVER, WS SPECIALISTS SHOULD APPLY IT TACTFULLY, SO THAT WORKERS REMAIN CO-OPERATIVE WHILE STUDIES ARE CONDUCTED IN THE PLANT.

  26. TECHNIQUES OF WORK STUDY: These are:1. METHOD STUDY is the systematic recording and critical examination of ways of doing things in order to make improvements. THUS it simplifies the job and develops more economical method of doing it.2.WORK MEASUREMENT is the application of techniques designed to establish the time for a qualified worker to carry out a task at a defined rate of working.THUS it determines how long it should take to carry out the work.

  27. BASIC PROCEDURE OF WScomprise of following STEPS:1.SELECT the job/task/process to be studied.2.RECORD all the relevant data/facts about the selected job.3.EXAMINE the recorded facts critically by challenging its purpose, place, sequence, person, and method.4.DEVELOP new methods,as alternative methods, of doing the selected job. 5.EVALUATE results of different alternative solutions. 6.DEFINE the new method and present it to the concerned people. 7.INSTAL the new method and provide training to the concerned staff . 8.MAINTAIN the new standard practice and establish control procedures.

  28. ACCORDING TO BARNES: Since Methods Engineering is a form of CREATIVE PROBLEM SOLVING, THE GENERAL PROBLEM SOLVING PROCESSES can be employed in WS also. Accordingly, following FIVE STEPS can be used: 1.Problem definition : Statement of the purpose/goal 2. Analysis of the problem : Fact-recording no evaluation 3.Search for possible solutions : Finding several alternative solutions. 4. Evaluation of alternatives : Examining which alternative meets the goal/criteria most, in order to evolve the preferred solution. & 5. Recommendationfor action: Communicating the details ,related to the preferred method to all concerned.

  29. LECTURE : 9-10 CHAPTER : 6 METHOD STUDY & JOB SELECTION

  30. STEP I : JOB/TASK/PROCESS SELECTION It involves following considerations: 1. ECONOMIC CONSIDERATIONS 2. TECHNOLOGICAL CONSIDERATIONS and 3. HUMAN CONSIDERATIONS

  31. Contd. 1.ECONOMIC CONSIDERATIONS Cost effectiveness i.e. to check whether or not the WS application would pay. For this, key-profit giving/ costliest operations with largest waste/scrap should be attacked first. Next bottleneck operations, repetitive operations, repeated material handling operations should be studied. For locating most important operations, PARETO ANALYSIS could be used.

  32. 2.TECHNICAL/TECHNOLOGICAL CONSIDERATIONS The analysis involves application of WS for the selection of the operations/processes where new technology e.g. automation/ robotisation should be introduced.

  33. 3.HUMAN CONSIDERATIONS Analysis involves location of those operations which present the sources of dissatisfaction and/or annoyance to the workers due to fatigue or monotony or unsafe environment or a work which is clumsy in nature.

  34. LECTURE : 11-12CHAPTER : 7RECORDING THE FACTS :DIAGRAMS & CHARTS

  35. STEP II : RECORDING THE FACTS Related to the existing process/ job ALL THE FACTS should be recorded ACCURATELY. TOOLS OF FACT-RECORDING are: (A) CHARTS,which may be oftwo types: (i) Based on SEQUENCE: (a) Outline Process Chart (b) Flow Process Chart (c) Two-Handed Chart ( or Operation Chart / Left Hand & Right Hand chart)

  36. CONTD. (ii ) Based on TIME scale: (a) Multiple Activity Chart (b) SIMO ( SImultaneous MOtion) Chart (B) DIAGRAMS: which may be of the following types: Flow diagram,String Diagram, Travel Chart, Cyclegraph, & Chronocyclegraph,

  37. PROCESS CHART SYMBOLS ASME has recommended FIVE standard symbols to be used on Process Charts, given below: • OPERATION :Main steps of the task /job involving modification /change. 2. INSPECTION: Checking quality / quantity. • TRANSPORTATION : For movement of persons/materials. • DELAY (TEMPORARY) : For waiting time of operators or materials. 5. STORAGE (PERMANENT DELAY)] : For controlled storage involving authorized issue/receipt of material etc. NOTE:FOR TWO PARALLEL EVENTS, BOTH ARE SHOWN IN ONE JOINT OR COMBINED SYMBOL: e. g. operation & inspection ,jointly are shown by symbol, indicated in the figure.

  38. THE OUTLINE FLOW PROCESS CHART • It uses ONLY TWO SYMBOLS: & • It provides an OVERALL PICTURE of the process / job / task. • Primarily it is used to show the sequence of operations & inspections for a MANUFACTURING or an ASSEMBLY kind of jobs.

  39. FLOW PROCESSCHART • It uses ALL THE FIVE SYMBOLS and provides the total sum details of the process/job under study. • A Flow Process chart may be of the following types: 1.MAN-TYPE in which every symbol is related to his/her activity only. 2.MATERIAL TYPE in which every symbol is related to the material of the job or a document (e.g. in offices) or a machine/equipment. • Data / information in a flow process chart are recorded in specifically designed FORM, as given in the TEXT BOOK / CLASS ROOM.

  40. LECTURE : 13-14CHAPTER : 7 (CONTD)

  41. STEP III : CRITICAL EXAMINATION The facts recorded in the Flow Process Chart are now EXAMINED CRITICALLY by applying the QUESTIONING TECHNIQUE, which involves the following SEQUENCE:

  42. CONTD. • PURPOSEfor which the activity is done • PLACE at ,, ,, ,, ,, ,, • SEQUENCE in ,, ,, ,, ,, ,, • PERSON by whom ,, ,, ,, ,, ,, • MEANSby which ,, ,, ,, ,, ,, WITH THE OBJECTIVE OFELIMINATING/ COMBINING/ REARRANGING/ SIMPLIFYING THE ACTIVITIES INVOLVED IN THE PROCESS. QUESTIONING TECHNIQUEinvolves 1. PRIMARY QUESTIONS and 2. SECONDARY QUESTIONS explained below:

  43. PRIMARY QUESTIONS According to the QUESTIONING TECHNIQUE the PRIMARY QUESTIONS are as follows: • Purpose-based: WHAT is actually done? WHY is the activity ELIMINATE necessary, at all? • Place-based: WHERE is it being done? WHY at this place? • Sequence-based: WHEN is it done? WHY at that time? COMBINE or • Person-based: WHO is doing it ? REARRANGE WHY by this person? • Means-based: HOW is it being done? SIMPLIFY WHY in that particular way?

  44. SECONDARY QUESTIONS • Corresponding to each answer obtained through the PRIMARY QUESTIONS further questions are raised to explore about the ALTERNATIVES i. e. alternate purpose, place, sequence, person & means. This methodology makes use of the SECONDARY QUESTIONS given as follows:

  45. Contd. • WHAT ELSE might be done? • WHERE ELSE might it be done? • WHEN ELSE might it be done? • WHO ELSE might do it? & • HOW ELSE might it be done? BY ANSWERING THE PRIMARY & SECONDARY QUESTIONS WE USE THE SYSTEMATIC CRITICAL EXAMINATION IN ORDER TO EVOLVE A BETTER METHOD OF DOING THE WORK.

  46. Contd. AS A RESULT, ONE CAN DEVELOP A BETTER METHOD IN LIGHT OF THE OBTAINED ANSWERS TO THE FOLLOWING QUESTIONS: • WHAT should be done? • WHERE should it be done? • WHEN should it be done? • WHO should do it ? • HOW should it be done?

  47. LECTURE : 15-17CHAPTER : 8RECORDING MOVEMENT OF WORKERS/MATERIALS

  48. RECORDINGMOVEMENT OF WORKERS/MATERIALS TOOLS USED FOR THIS PURPOSE ARE: • STRING DIAGRAM • FLOW DIAGRAM • TRAVEL CHART

  49. STRING DIAGRAM • IT IS A SCALE PLAN OR MODEL ON WHICH A THREAD OR STRING IS USED TO TRACE AND MEASURE THE PATH OF WORKERS/ MATERIALS DURING A SPECIFIED SEQUENCE OF EVENTS. • LENGTH OF THE THREAD/STRING MEASURES THE DISTANCE MOVED.

  50. FLOW DIAGRAM • It is a FLOOR-PLAN showing the path of travel of the operator or the material, through the plant. • It ALSO indicates the direction of travel by means of arrows, drawn on the diagram.

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