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Work Study

Work Study. Knowledge dealing with the systematic determination of a preferable work method with the time required for the uses of human and equipment to perform such work as well as a development of material & tools to make the established method and time practical. Work Study.

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Work Study

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  1. Work Study Knowledge dealing with the systematic determination of a preferable work method with the time required for the uses of human and equipment to perform such work as well as a development of material & tools to make the established method and time practical

  2. Work Study Process Analysis Operation Analysis (Micro) Motion Study Time Study Work Instruction Establishing

  3. Time Study Procedure to determine a certain amount of time required to perform a task involving either human or machine under certain standard conditions of measurement Which consider Specified work method Well trained worker Normal pace Allowance Linked from Motion Study

  4. Time Study: A Trial 30 min.

  5. Time Study Concept: A Fair Day’s Work Required Responsibilities Operator Supervisor WIN - WIN Union Analyst

  6. Time Study Techniques • Direct time study • Predetermined time systems (PTS: Work factor, MTM) • Standard time data • Work Sampling

  7. Direct Time Study • General equipment • Stopwatch 1/100 or 1/60 • Observation sheets • Calculator • Computer Options Time study board Electronic data collector Electronic time recorder Micromotion picture or Video camera Time study software Tachometer

  8. Making a Study (1) Preparation • Select an operator • Make sure the operator will cooperate with the study • Collect information about the operation and layout • Divide the operation into elements • Describe each element in detail

  9. Operator & The operation Operator • A well trained one • Morale & Understanding • Roles of Supervisor The Operation • Standardized method • Proper working environment • Smooth equipment operations

  10. Elements of the operation Description • Headlines of the observation sheet • Sketch of the part and the workplace Operation Breakdown -- Work Element • Describe beginning and end points definitely • Measurable by stopwatch (0.04 - 0.35 min) • Apply rating factor and allowance separately • Establish time standard for each element

  11. Elements of the operation Types of Element • Regular element VS Intermittent element happens every cycle • Inside work element VS Outside work element happens during the machine operation • Constant element VS Variable element vary with load/ shape of work piece

  12. Making a Study (2) Time Recording • Make a trial time recording for each elements of the operation (5, 10 cycles) • Calculate a sufficient number of cycles for the study • Record the time of each elements as per the number of required cycles • Ensure the accuracy and confidential level for the representative time of each elements

  13. Time Recording Make sure that every parts of the operation are included For each element • Trial reading • Required number of cycles • Representative time • plus/minus 5% Accuracy • 95% Confidence level Stopwatch reading • Continuous timing • Repetitive timing (snap back) • Accumulating timing Observation sheets

  14. Time Study Observation Sheet 1: Continuous timing No. of cycles (Maytag)

  15. Time Study Observation Sheet 2 (Snap back method)

  16. X bar How many observations is enough? Consider R Number of Time Study Readings: Maytag Trial Readings (5 or 10 cycles) R = Range = Max - Min X bar = Mean = Average or (Max + Min)/ 2 Completed Sheet

  17. +/- 5% Precision & 95% Confidence Level of the readings

  18. Total No. of observation needed: The Final check

  19. Completed Time Study Observation Sheet Maytag Allowances

  20. Representative Time, RT Assure the total number of observations according to the desired accuracy and confidence level Normal dist: to estimate RT within 95% CI and 5% accuracy Representative Time, RT(Selected Timeor Basic Time) RT = mean / mode of observed times

  21. Making a Study (3) Standard Time Calculation • Calculate representative time • Rate the operator’s performance and apply it to representative time, getting a normal time • Calculate allowances • Obtain standard time by adding the allowances to normal time

  22. Performance Rating To indicate the rating factor, an adjusting factor Evaluate the operator’s speed for doing such element in relation to the normal speed Normal Speed, Normal Pace: ???

  23. Rating Factor: Cautions!!! • Normal Pace -- some standard activities • Variety of natural speed among people • Various available systems, performance rating 100 • Separately rate on different elements of operation • Judgement of the analyst • Tailor your own “normal” Not only the analyst rates the operation, but also the involved operators/mgrs.

  24. Rating System • Skill and Effort • Westinghouse System • Synthetic • Physiological Evaluation of Performance Level • Performance Rating • Company Standard and etc.

  25. Rating Scales Scale A: Normal 100% (0-100-115:145-200) Scale B: Normal 60 points (0-60-70:87-120) Scale C: Incentive 125% (0-100-125-200) Scale D: Incentive 100% (0-80-100-160)

  26. Performance Rating Scales: A-B-C-D

  27. Normal Time = Representative Time x RF (in %) 100 Apply Rating Factor Normal Operator: A qualified and experienced operator working under customary conditions at the workstation, at a pace neither too fast nor too slow, but representative of average. Completed Sheet

  28. Allowances Personal : person Fatigue : working environment , length of period Delay : equipment, material flow, management Personal allowances • personal needs • nature of work • 2-5 % of 8 hours, or more?

  29. Allowances Fatigue allowances • not necessary happen • ILO standard • refreshment breaks Delay allowances • avoidable • unavoidable • allocation techniques

  30. Allowances Table

  31. Standard Time = Normal Time x 100 (100 - AF,in %) Apply Allowances Standard Time: The time that a qualified and well trained operator working at a normal pace will need to complete one cycle of the operation Standard Time = Normal Time x (1+ AF,in %)

  32. Normal Time = Representative Time x RF (in %) 100 Standard Time = Normal Time x 100 (100 - AF,in %) Direct Time Study: Summary Representative Time = mean / mode of observed times Standard Time = Normal Time x (1+ AF,in %)

  33. Uses of Standard Time • Evaluation of alternative methods • Labor cost control and manpower planning • Overhead cost estimation and budgeting • Production scheduling: CPM • Production line balancing • Plant layout and plant capacity • Training and performance evaluation • Output-based incentive scheme design

  34. Work Instruction Work Study Motion Study creates preferred method for work so called Standard Method. Based on standard method, Time Study creates Standard Time.

  35. Work Instruction Reduce Variation • Planning & Controlmanpower, line balancing, scheduling, budgeting, plant layout, plant capacity • Operating Knowledge • Training & Learning • Performance Standard & Evaluation • Incentive Scheme Allowances

  36. Taxonomy: the guideline Ind. Firm Plant Dept Group Indv’l • MA • MF MF MF • MF MF MF • MC MC MC MC • MC MC MC MC • WM WM Min Hrs Days Wk Mth Qtr Year

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