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Chapter 4

Chapter 4. Maintenance Work Measurement. Chapter Objectives. 1. Enable students to understand the role standard time plays in improving maintenance systems 2. Enable students to understand the basic techniques for developing Standard times for maintenance work.

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Chapter 4

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  1. Chapter 4 • Maintenance Work Measurement

  2. Chapter Objectives 1. Enable students to understand the role standard time plays in improving maintenance systems 2. Enable students to understand the basic techniques for developing Standard times for maintenance work

  3. Chapter 4 Objectives 3. Enable students to evaluate the adequacy of the existing time standards maintenance programs. 5. Enable students to use time standards effectively in maintenance

  4. Role of Standard Times (ST) • 1.  Aid in evaluating the performance of workers • 2. Enable effective planning and control of maintenance resources. • 3. Aid in scheduling • 4. Enable management to gauge productivity.

  5. Time Standard • It is the required time by a qualified worker working at standard pace to perform a job. • Qualified worker is one who has acquired the necessary skills, knowledge and other attributes necessary to carry out the work to satisfactory standard of quantity, quality and safety.

  6. Time standards • Standard pace ( performance ) it is the rate that a qualified worker naturally will achieve as an average over the working day.

  7. Nature of Maintenance Work • Occurs randomly • High variation • Various places • Varying environmental conditions

  8. Time study Time study is performed by timing the worker as the job is performed, summing the times for the pertaining elements of the job, standardizing the observed times and adding allowances for personal and other working conditions.

  9. Steps of Time Study 1. Select the job ( Standardize the job in terms of material and the operator ) 2. Break the jobs into elements 3. Observe the job 4. Compute the basic time ( BT = OT * ( Rating/ Standard rating) BT = Basic time, OT = Observed time Standard rating = 100%

  10. Steps of Time Study 5. Determine allowances 6. Establish job standards Job Standards = BT( 1 + ALL) ALL = Allowances Table 4.3 provides guidelines for allowances.

  11. Work Sampling • Work sampling is a technique for finding the percentage occurrence of a certain activity using statistical sampling. • It can be applied to see the utilization of a maintenance worker, machine utilization, etc.

  12. Example A worker is observed randomly 1000 times. In 750 times he was busy. In 250 he was idle. Utilization = 750/1000 = 0.75 Confidence interval for utilization is

  13. Planning work Sampling study • Define clearly the objective of the study • Determine the population of the study. • Activity definition • Observation form design • Observation route planning

  14. Planning work Sampling study 6. Fix study schedule 7. Determine number of observations 8. Observation time schedule 9. Sample population preparation 10. Observer training

  15. Predetermined Motion – Time Systems Pre-determined motion time systems are used for setting job standards. One of the better known pre-determined motion times systems is the Method-Time Measurement (MTM). The fundamental motion times are the result of studying a large sample of diversified operations 

  16. Predetermined Motion – Time Systems For setting a job standard, an analyst would break the job into the basic motions required to perform it and then sum the appropriate pre-determined times for all the basic motions involved.

  17. Procedure for Setting a Predetermined Standard 1. Observe the job or think it through if it is yet to be establish 2. Break the job into elements and record each element. 3. Obtain time units for each job element from the tables. 4. Add the total motion units for all elements.

  18. Procedure for Setting a Predetermined Standard 5. Estimate allowance for personal time, delays and fatigue.  6. Add the performance motion time and allowance units for a standard job motion unit together and compute the motion units to actual time in minute, hour etc. PMTS can be used for developing job standards even before the work get started.

  19. Standard Data Standard data refers to standard data banks for various elements which occur repeatedly in the workplace. These elements can be put together to develop job standards.

  20. Developing standard Data Several maintenance jobs in a company may contain the same work elements. It is not necessary to time these work elements in every job if a reasonable job standard has been determined from one or more previously studied jobs. In the maintenance department a data base can be maintained for work element duration obtained through previous time studies or by pre-determined motion time systems

  21. Estimation Estimating is the process of using past experience to predict future events. It can be used to develop job standards in an expensive way. Advantage and Disadvantage of this method

  22. Comparative Estimating ( Slotting) The basis of comparative estimation is its reliance on a series of benchmark jobs. These benchmark are jobs, representative of a range of jobs, which are similar in work requirement, types of tools used etc. and are capable of being measured by accepted time measurement techniques

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