me-2 notes
TRANSCRIPT
AA
CONTENTS
QUESTION BANK
PAGE NO:-(3-8)
Unit – I
PAGE NO:-(9-15)
Unit – II
PAGE NO:-(16-23)
Unit – III
PAGE NO:-(24-28)
Unit – IV
PAGE NO:-(29-33)
Unit – V
PAGE NO:-(34-48)
Unit – VI
PAGE NO:-(49-53)
QUESTION
UNIT – I
Q. 1
What do you mean by work content? What are the various factors that are responsible for exam work content and how this can be reduced? Explain with suitable examples?
Q. 2 How is ineffective time of a job reduced?
Q. 3
How productivity is defined in different ways? What is need of different definition? Illustrate their importance!
Q. 4
Differentiate between production and productivity?
Q. 5
How are productivity and standard of living interrelated? Explain with suitable example?
Q. 7
Write short note on:
Productivity in the individual enterprise
Q. 8
What do you mean by ‘Total work content’?
Q. 9
“Productivity is a mean for increasing the welfare of the nation”. Justify the statement.
QUESTION
UNIT – II
Q. 1
Explain the following terms :
(a) Total Productivity Index
(b) Partial Productivity Indices
(c) Total Factor Productivity Index
Q. 2
Write short note on:
“Total Productivity Model” (TPM)
Q. 3
Write short note on :
“American Productivity Centre (APC)
Q. 4
Explain the lease service concept of capital used by CRAIG and HARRIS?
Q. 5
Write short note on :
“Different level of productivity measurements”
Q. 6
Write the benefits of productivity measurement in an organization?
Q. 7 Enlist the factors influencing productivity?
Q. 8
Derive the relation between Total Productivity of a firm and Productivity of Individual Product?
Q. 9
Derive total productivity of product in terms of its partial productivities?
QUESTION
UNIT – III
Q. 1
Explain the concept of MOST?
Q. 2
Give a brief account of the Awareness – Improvement - Maintenance process (AIM)
Q. 3
What do you mean by objective in OMAX? Explain.
Q. 4
With neat sketch explain the basic structure of objective matrix. Also comment of :-
(i) Productivity criteria
(ii) Performance scores in OMAX
QUESTION
UNIT – IV
Q.1
Explain the concept of work-sampling?
Q.2
What are the advantages and disadvantages of sampling techniques?
Q.3
State the complete sampling procedure in terms of various steps?
Q. 4
What is use of control chart in sampling? Explain in details?
Q. 5 Discuss the various application of work sampling?
Q. 6
What do you mean by confidence levels in work sampling?
QUESTION
UNIT – V
Q. 1
Explain in brief the eight standard work elements mentioned in work factors system?
Q. 2
What are the variables in WORK FACTOR SYSTEM? Explain Work factor techniques in brief?
Q. 3
Write short note on :
“PREDETERMINED MOTTON TIME SYSTEMS” ‘PMTS’
Q. 4
Briefly describe MTM system?
Q. 5
Define the following :
(1) MTM – 1
(2) MTM – 2
(3) MTM – 3
Q. 6
In MTM system, state and discuss the basic manual motion?
Q. 7
Explain the following terms :
(i) RL 1
(ii) RL 2
(iii) P1 NSD
(iv) P2 NSD
(v) P2 SSE
(vi) P1SE
(vii) T30S
(viii) T90L
(ix) R4A
(x) R8C
(xi) R10C
(xii) R12AM
(xiii) MIOB15
(xiv) M16B15
(xv) M16AM
(xvi) M6A
(xvii) MM10C
(xviii) G1A
(xix) G2A
(xx) G3A
(xxi) G4A
(xxii) ET 14/10
QUESTION
UNIT – VI
Q. 1
Write short note on :
“Standard Data”
Q. 2
What is multi-factor incentive plan? How it can be applied to transfer machine operation? Discuss the advantages of multi-factor Wage Incentive System.
Q. 3
Write short note on :
“Necessity of Training Programs”
Q. 4
Write short note on :
“Computer Application in Work Study”
UNIT – I
Q. 1
What do you mean by ‘work content’? What are the various factors that are responsible for excess work content and how this can be reduced? Explain with suitable examples?
Ans:
Work content of a product/Job means the amount of work contained in a given product of process and normally measured in man hours.
Work content has two content :
(a) Basic work content
(b) Excess work content
a)
Basic Work Content :
Basic work content implies the minimum times theoretically required to do an operation or job. This cannot be reduced. Basic work content will result in the following condition:
§ The design and the specification are perfect.
§ Process of manufacture is exactly followed.
§ No loss of working time due to any of the reasons.
b)
Excess work content :The actual time required completing an operation or job is more than the basic time in practical situation. 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.
§ Bad design of the product.
§ Lack of standardization of components.
§ Incorrect specifications and quality standards.
§ Faulty design of components.
b)
Work content added due to inefficient methods of manufacture.
§ Wrong selection of tools.
§ Lack of process standardization.
§ Improper layout of the shop.
§ Inefficient methods of material handling.
c)
Ineffective time added due to short comings of the management.
§ Bad working conditions.
§ Lack of safety measures.
§ Improper communication.
§ Shortage of materials.
d)ineffective time added due to reasons attributed to work man.
§ Unauthorized absence from work.
§ Substandard performance.
§ Carelessness in working.
§ Unnecessary wastage of time.
Techniques to reduce work content :
a)
Management techniques to reduce work content due to product.
§ Product development
§ Standardization
§ Value analysis
§ Market research
b)
Management techniques to reduce work content due to process of methods.
§ Process planning
§ Methods study
c)
Management techniques to reduce ineffective time due to management.
§ Product specialization
§ Production planning and control
§ Plant maintenance
§ Safety measures
d)
Management techniques to reduce ineffective time with control of the workers.
§ Sound personnel policies
§ Operators training
§ Safety training
§ Financial incentives
Q. 2
How is ineffective time of a job reduced?
Ans :
It depends upon the worker as how usefully and fully he utilizes the time available to him for performing a job. A worker can save time mainly by reducing the amount of time wasted, when he is resting, smoking, talking to his fellow workers, waiting to clock off, being late or absent etc. to reduce the ineffective time, that is with in the control of the worker the efforts of the management might help in this direction.
The following are the management techniques that can reduce ineffective time totally if all these techniques are perfectly applied :
a)
Marketing and Specialization reduce idle time due to product variety.
b)
Standardization reduces idle time due to short runs.
c)
Product Development reduces ineffective time due to changes in design.
d)
Material Control reduces idle time due to lack of raw materials.
e)
Maintenance reduces idle time of men and machines due to breakdowns.
f)
Improved Working Conditions enable workers to work steadily.
g)
Sound Personnel Policy and Incentives reduce ineffective time due to absence.
h)
Safety Training reduces ineffective time due to accidents.
Hence, management has a very great responsibility for reducing the ineffectiveness due to bad attitudes of mind on the part of workers by adopting suitable personnel policy and providing proper training to supervisory staff.
Q. 3
How productivity is defined in deferent ways? What is need of different definitions? Illustrate their importance?
Ans :
Productivity is a term that has a number of different meanings although it is most commonly associated with labour effectiveness in industry.
In broad sense productivity is the ratio of output to some or all of the resources used to produce the input.
Productivity can be expressed as :
Productivity = Output
Input
Some definitions of productivity are given below :
a)
Productivity is nothing but the reduction in the wastage of the resources.
b)
Productivity is an attitude of mind.
c)
Productivity is the faith in human progress.
d)
Productivity is the multiplier effect of efficiency and effectiveness.
e)
Productivity is a means for increasing the welfare of the nation.
f)
Productivity is the constant adaptation of economic and social life to changing conditions.
The need of different definitions required to explain the fundamental concept of productivity.
Importance of Productivity :
The productivity is of great importance, specially for under developed and developing countries, since it is a measure of how well the resources are utilized to get the maximum output.
Productivity analysis is related with the stages and situations where improvement in the working with inputs is possible in order to increase output.
Q. 4
Differentiate between production and productivity?
Ans :
The concept of production and productivity are totally different.
§ Production refers to absolute output whereas productivity is a relative term where in the output is always expressed in terms of inputs.
§ Production may improve without the corresponding improvement in the productivity and vice-versa.
§ If the production is increased for the same output, then there is an increase in productivity.
§ Production means the output interns of money whereas productivity is the efficiency of the system used for production.
Q. 5
How are productivity and standard of living interrelated? Explain with the help of suitable example?
Ans:
The standard of living means the degree of material well-being available to a person or class or community which is necessary for sustaining and enjoying life. The standard of living of the representative person of family in the different countries of the world varies greatly from country to country, from community to community. The basic needs that must be met in order to attain a minimum decent standard of living are :
§ Food
§ Clothing
§ Shelter
§ Security
§ Essential Services
The greater the amount of goods and services produced in any community the higher its average standard of living will be.
There are two main ways of increasing the amount of goods and services produced. They are ;
§ Increase employment
§ Increase productivity
If in any community men and women who wants to work and are unable to find work or who are able to find only part time work, the output of goods and services can be increased if full-time productivity work can be provided to them i.e. if employment can be increased. Whenever there is unemployment, efforts should be made to increase employment which should go hand in hand to increase the productivity.
By increasing such we can have :
§ More and cheaper food by increasing the productivity of agriculture.
§ More and cheaper clothing and shelter by increasing the productivity of the industry.
§ More security and essential services by increasing all productivity.
Productivity is the ratio of output to some or all of the resources used to produce the input. These resources may be :
§ Land
§ Material
§ Plant, machines and tools
§ The services of men
The productivity has great importance since it is a measure of how well the resources are utilized to get the maximum profit. An increase in production does not indicate an increase in productivity. If input increases by a greater percentage than output, higher production will be achieved at the expense of a reduction in productivity. Hence, higher productivity means that more is produced with the same expenditure of resources at the same cost in terms of land, materials machine etc.
Hence, it is dear from the above discussion that higher productivity can contribute to a higher standard of living. If more is produced at the same cost, or the same amount is produced at less cost, there is a gain to the community as a whole, which can be used by members of the community to acquire more and better goods and services and to improve their standard of living.
Q. 6
Explain “Six lines of attack” to improve productivity?
Ans:
The same means which will improve the productivity of an individual industry, can be considered to be the means for improving productivity in the industries of the country as a whole. The following are the six effective means of productivity improvement.
(i) Simplify the product or service. Reduce and standardize the range.
(ii) Improve basic process by research and development.
(iii) Use better machinery, equipment and tooling.
(iv) Improve existing methods of plant operation and equipment usage.
(v) Improve the work planning through work study.
(vi) Increase the effectiveness of all employees through ergonomics approach.
The means of serial numbers (i), (ii) and (iii) require long term strategies and may require heavy investments.
The means of serial number (iv), (v) and (vi) require medium and short term strategies and may require relatively smaller investments.
Q. 7
Write short note on
Productivity in the individual enterprise
Ans :
There are number of factors affecting the productivity of an enterprise. These are:
a)
Factors which are outside and cannot be controlled by the enterprise :
§ General level of demand for goods.
§ Taxation Policy
§ Interest rates
§ Availability of raw materials
§ Suitable equipments
§ Skilled labour
b)
Factors which are inside and can be controlled by the enterprise :
§ Resources at the disposal of an enterprise.
§ The task of the management
§ The productivity of materials
§ The productivity of land, buildings, machines and manpower.
§ How the total time of a job is made up.
§ Factors tending to reduce productivity
Q. 8
What do you mean by ‘Total work content’?
Ans:
Total work content is defined as the difference between the total time of operation under existing conditions to that of total ineffective time.
Q. 9
“Productivity is a mean for increasing the welfare of the nation”. Justify the statement.
Ans:
At the national level, productivity is a mean for increasing the welfare of the nation. It implies production of more goods or services from the same input resources in the same amount of time. Each nation must be in a long run, by self supporting. The standard of living achieved by the citizen through his own efforts. The greater the amount of goods and services produced in any community the higher its average standard of living will be.
There are two ways of increasing the amount of good and service produce they are :
§ Increase employment
§ Increase productivity
If we improve our output of good and services per person by just 2 percent per year, the cumulative effect of that annual 2 percent increase would produce a 724 percent increase in productivity in 100 years. It is the rate of productivity improvement over such periods of time that determines a nation’s program.
It is the result of continuos productivity improvement efforts over the past 100 years in the United States of America that today the country is the greatest industrial nation in the world.
UNIT – II
Q. 1
Explain the following terms:
a) Total Productivity Index
b) Partial Productivity Indices
c) Total Factor Productivity Index
Ans:
(a) Total Productivity Index :
Total Productivity index for a given period
=
measured-period output in base-period prices
measured-period inputs in base-period prices
Where the sum of inputs in base-period prices = output in base-period prices in the base period, and the difference between the sum of inputs in base-period prices and the output in base-period.
The benefits of the total productivity index are as under:
§ Easy and more accurate representation of the total picture of the company.
§ Easily related to total costs.
§ Consider all quantifiable outputs and inputs.
The limitations of the total productivity index are as under:
§ Difficulty in obtaining the data.
§ Requirement of special data collection system.
(b) Partial Productivity Indices :
Depending upon the individual input partial productivity measures are expressed as :
Partial Productivity
=
Total Output
Individual Input
Labour Productivity
=
Total Output
Labour Input
Where, labour input is measured in terms of man-hours.
Capital Productivity
= Total Output
Capital Input
Material Productivity
= Total Output
Material Input
Energy Productivity
= Total Output
Energy Input
The benefits of the partial productivity indices are as under :
§ Easy to understand and calculate
§ A tool to pinpoint improvement.
The limitation of the partial productivity indices are as under :
§ Misleading if used alone
§ No consideration of overall impact
(c) Total Factor Productivity Index :
It is the ratio of net output to the labour and capital input.
Total Factor Productivity Index
= Net output
labour + capital inputs
The benefits of the total factor productivity index are as under :
§ Data from company records is relatively easy to obtain.
§ Value added approach.
The limitations of the total factor productivity index are as under:
§ No consideration for material and energy input.
§ Difficult to relate value added approach to production efficiency.
Q. 2
Write short note on:
“Total Productivity Model” (TPM)
Ans:
The total productivity model (TPM) is a basic model from which several versions are derived. It is based on a ‘total productivity’ measure and a set of five partial productivity measures. The model can be applied in any manufacturing company or any service organization.
The basic TPM has three versions associated with it:
(a) Operational total productivity model (OTPM)
(b) Approximate total productivity model (ATPM)
(c) Comprehensive total productivity model (CTPM)
Total productivity, as we define it in the TPM is given by the following:
Total productivity
= Total tangible output
Total tangible input
Where,
Total tangible output
=
Value of finished goods produced + value of partial units produced + dividends from securities + interest + other income
Total tangible input
=
Value of (human + material + capital + energy + other inputs) used.
The word tangible here refers to measurable.
The tangible output and tangible input have to expressed in value terms because all the output and input elements are not in the same units.
For e.g. the human and energy input may be expressed in man-hours and kilowatt hours.
The salient features of the TPM are as follows:
§ It provides both aggregate and detailed productivity indices.
§ Helps to find out the performance and productivity of the operational unit.
§ Helps to plan, evaluate and control.
§ It provides valuable information to strategies planners in making decisions.
Q. 3
Write Short note on :
“American Productivity Centre” (APC)
Ans:
American productivity centre (APC) has developed a comprehensive measure which distinguishes among profitability, price recovery and productivity. It can be utilized to measure productivity changes in labour, materials, energy and capital. It also measures the corresponding effect each one has on profitability.
APC model is based on the premise that profitability is a function of productivity and price recovery. Productivity relates to quantities of output and quantities of inputs, while price recovery relates to price of output and cost of inputs. Price recovery can be thought of as the degree to which input cost increases are passed on to the customers in the form of higher output price.
Relationship between productivity, profitability and price recovery are represented by :
Profitability
= Revenue
Cost
Output Quantities x Sales Prices
Input Quantities x Unit Lost
Output Quantities
x
Sales Price
Input Quantities
Unit Cost
\ Profitability = Productivity x Price recovery.
The model compares data from one period with the data from the current period.
Q. 4
Explain the lease service concept of capital used by CRAIG & Harris?
Ans:
This model points out the inadequacy of partial productivity measure. It is also called as “Service flow model” because physical inputs are converted into rupees that are payments for services provided by inputs. Productivity is viewed as efficiency of conversion process.
Total productivity is expressed as,
P
= O
L + C + R + Q
Where,
P
= Total productivity
L
=
Labour input factor
C
=
Capital input factor
R
=
Raw material and purchased parts
Q
=
Other wise, good and services.
The Craig-Harris Model uses a lease service concept of capital rather than a physical consumption approach. All revenue items are included as outputs and all cost or expense items as inputs. Finally, the model emphasizes a total productivity concept rather than partial productivity measures.
Thus, the Craig-Harris model is a major improvement in the treatment of capital input.
Q. 5
Write short note on:
“Different levels of productivity measurement are as under”:
Ans:
The different levels of productivity measurements are as under:
(a) International level
(b) National level
(c) Industry level
(d) Company level
(e) Individual Resource level
a) International level
Development of indexes to compare the growth and competitive position of competing countries.
b)
National level:
Developing economic indicators to enable the country to plan its resources on a rational basis.
c)
Industry level:
Developing measures to compare performance of companies which comprise the industry in a sector.
d)
Company level:
To measure trends of productivity improvement to plan effectively company resources.
e)
Individual Resource level :
To develop measures to compare performance of each resource among one another. To plan the future requirement of there resources.
Q. 6
Write the benefits of productivity measurement in an organization?
Ans:
Productivity measurement in an organization can have the following benefits:
a)
The organization can assess the efficiency of conversion of its resources so that more goods or services are produced.
b)
The economic and non-economic objectives of the organization can be re-organized.
c)
Planned productivity-level targets for the future can be modified.
d)
Strategies for improving productivity can be determined.
e)
Productivity values generated as a result of a measurement.
f)
Measurement creates competitive action.
Q. 7
Enlist the factor influencing productivity ?
Ans:
Factors influencing productivity can be classified broadly into two categories :
a) Controllable or internal factors
b) Non-controllable or external factors
a)
Controllable (Internal factors) :
§ Product
§ Plant and Equipment
§ Technology
§ Materials
§ Human Factors
§ Work Methods
§ Management Style
§ Financial Factors
§ Sociological Factors
b)
Non-controlled (External factors) :
§ Structural Adjustment
§ Natural Resources
§ Government Policy
§ Infrastructure
Q. 8
Derive the relation between Total Productivity of a firm and Productivity of Individual product?
Ans:
By definition, total productivity of a firm is the ratio of total output of the firm to the total input used.
TPF =
å Oi
å Ii
But,
å Ii
=
å å ij
i i j
\TPF =
å Oi
= Total productivity of the firm
↳ (1)
i
å å ij
i j
Since,
TPi
= Oi
å I ij
i
\Oi = T Pi å Iij
i
Substituting the value of )I in equation
TPF =
å (Tpi) (å I ij)
i
å å I ij
i i
=
å (TPi) å Iij
i
å å Iiy
\ TPF = å (TPi) x
Ii
i IF
=
å (TPi) (Wi)
i
Where,
Wi =
Ii
IF
\
TPF = å Wi TPi
i
Q. 9
Derive total productivity of product i in terms of its partial productivity?
Ans:
We define total productivity of product i as the ratio of the total output value to the total input cost.
TPi =
Oi
=
Oi
Ii
å Iij
PPij =
Oi
for all j
Iij
Oi = TPi å Iij
i
Oi = PPij. Iij
There,
TPi å Iij = PPij . Iij
TPi = PPij . Iij
å Iij
i
Let, Wij x POij for all j
Where ,
Wij denotes the weight.
UNIT – III
Q. 1
Explain the concept of MOST?
Ans:
An outgrowth of MTM (Methods –time Measurement) called MOST (Maynard Operation Sequence Technique) is a simplified system developed and originally applied at Saab-Scania in Sweden in 1967 by Kjell B Zandin.
H.B. Maynard and Company has introduced MOST system and this new system was brought into practice in the United States in 1975. It has gained a wide recognition as a major contribution to the body of Industrial Engineering. This techniques has a wide application and can be successfully applied in all industries ranging from ship building to electronics, automobile, textile. Application have been made in office, assembly shops, material handling, maintenance and other such operations.
The various levels of MOST are:
Maxi MOST :
At the higher level maxi-MOST is used to analyze operation that are likely to be performed lesser than 150 times per week.
Basic MOST :
At the Intermediate level, operation that are likely to be performed more than 150 times but lesser than 1500 times per week should be analyzed with basic MOST.
Mini MOST :
At the lowest level, mini-MOST provides the most detailed and precise methods analysis.
Application of Most:
This technique finds its application for method improvement. It helps to established the standards and also for determining the production delays and labour performance index
Q. 2
Give a brief account of the AIM Awareness – Improvement – Maintenance process?
Ans:
A three-phase process designed to foster the successes is known as AIM. It recommends events to create Awareness, activities that cause Improvement and measures for the maintenance of gains.
First Phase: Awareness
The first step toward reform is to convince people that improving productivity will benefit them personally. Employee should push productivity is the prime function of the awareness phase. Two start-up tactics are suggested namely:
(1) agitation
(2) auditing
1)
agitation :
To agitate is to excite. Getting everyone excited about productivity is the epitomes of awareness.
2)
auditing :
Audit delivers a message about an organizations current state and its dedication to improving its productivity.
Second Phase: Improvement
The phases of awareness and improvement tent to blend together. Four improvement parts are :
1) Investment
2) Incentives
3) Involvement
4) I.E. methods
1)
Investment :
It is the adoption of advanced technology. The first rule is to be objective.
The second rule is to conduct the economic analysis correctly.
The third rule is to consider an investment’s affect on productivity.
2)
Incentives :
A sure way to attract the attention of employees is to wave dollar bills. Attaching cash payments to productivity gains, commonly called productivity sharing is a powerful inducement for active participation.
3)
Involvement :
It is the idea of everyone working together and enjoying their works.
4)
I.E. methods :
Industrial engineering methods represents a very large family of procedural techniques and managerial practices used to make operations more productive.
Third Phase : Maintenance
To maintain is to support and preserve from decline. Maintenance of a productivity improvement process depends on measuring performance and monitoring performance and monitoring program.
Measurement::
An improvement process in easier to maintain when the participants have a clear goal to aim at.
Monitoring :
A productivity improvement process without benchmarks is a race without a times.
Q. 3
What do you mean by Objective in OMAX? Explain.
A measurement method called the objectives matrix (OMAX) is particularly appropriate to basic work units such as crews, departments and staff. It can also represent a complete organization. It can be conveniently applied to knowledge based activities that are considered difficult to measure, as well as skill-based work that can be metered by more conventional measures. It has been favorably received in manufacturing service and government sectors by both large and small organization.
The theory behind the objective matrix is that productivity is a function of several performance factor, each with distinct dimensions that very among work units, and the most practical way to assess unit productivity is to measure the most influential factors.
The salient features of the objective matrix are :
1)
Productivity Criteria :
Action and behaviors that promote productivity in specific jobs or work positions are characterized by ratios. There are the characteristics of performance.
2)
Performance :
Measurement of performance over a period of time are entered in this line.
3)
Ratings :
The body of the matrix is composed of levels of achievement.
4)
Score :
In the line immediately below the body of the matrix, the performance number, registered in the performance line immediately above the body, is converted to a score.
5)
Weight :
Importance ratings are attached to indicate their relative impact on the total organization’s productivity objective.
6)
Value :
The sum of weighted scores is the index for the period.
7)
Index :
The sum of weighted scores is the index for the period.
Q. 4
With neat sketch, explain the basic structure of objective matrix. Also comment on:-
1) Productivity criteria
2) Performance scores in OMAX
Ans:
Objective Matrix :
An objective matrix is a compact format within which performance goals originate and from which a profit of accomplishment takes form.
Structure of Objective Matrix :
I.
Productivity criteria:
Most employees know how their activities affect the productivity of work unit. They realize which of the function they perform support the organization’s output. These significant functions are the criteria of productive performance.
The seven broad classifications encompass most of the productivity criteria is as shown in the figure:
Quantity
Quality
Timeliness
Material yield
Resource Utilization
Safety
Operating Consistency
Productivity Criteria
i) Quantity :
output maximization
ii) Quality :
of goods and services (customer satisfaction)
iii) Timeliness :
elimination of delays
iv) yield :
Input minimization and waste avoidance.
v) Utilization :
Effective utilization of resources
vi) Group traits :
Individual and organizational properties that contribute to productive performance.
II)
Performance Score :
Performance sales in the body of the objectives matrix run from 0 to 10. There are thus eleven levels of accomplishment for each criterion a single criterion occupies a column that stretches from the top to bottom of the matrix. Levels of accomplishment extend across the body of the matrix as indicated by the rows marked from 0 through 10.
The scale is anchored by designated numbers at three levels:
§ Level 0 ®
The lowest level recorded for the criterion ratio over a recent period of time.
§ Level 3 ®
At the time the rating scale was established.
§ Level 10 ®
A realistic estimate of results that can be attained in the foreseeable future.
Level 0 and 3 are clearly defined benchmarks. Level 10 is the challenge.
UNIT – IV
Q. 1
Explain the concept of work-sampling?
Ans:
Work sampling was first used by L.H.C. Tippet in the British textile industry and it was introduced into this country under the name of ‘ratio delay’ in 1940. Work sampling is a fact-finding tool. Work sampling is defined as a method of finding the percentage occurrence of a certain activity by statistical sampling and random observations.
Work sampling has three main uses :
i)
Activity and delay sampling:
To measure the activities and delays of workers or machine e.g. the percentage of time in a day, a person is working and the percentage that a person is not working.
ii)
Performance sampling:
To measure working time and non-working time of a person on a manual work, and to establish a performance index or performance level for a person during his working time.
iii)
Work measurement: :
Under certain circumstances, to measure a manual task, that is, to establish a time standard for an operation.
Work sampling is based upon the laws of probability. A sample taken at random from a large population provides a good estimate of the distribution of the population because it tends to have the same distribution as the population.
Let us consider the following example :
A worker while working during his shift either does the job assigned to him or remain idle for one or the other reason the following table shows that out of total 50 observations there were 45 working observations and five idle observations.
State of worker
No of observations
Working
45
Idle
5
The table indicates the working time and idle time.
The idle time percentage would be =
5
x 100 = 10%
50
Working time would be =
45
x 100 = 90%
50
This investigation is for one worker for a shift of 8 hours a day and indicates that the operator was idle for 10% or 48% minutes in a shift of 8 hours (480 minutes) while working for 90% or 432 minutes in one shift.
Some more examples are as under :
i) A decision regarding the cooking of rice is taken by having a sample of rice from a boiling/cooking pot and pressed between fingers.
ii) A decision regarding the quality of wheat bag to be purchased is made by examining a sample of wheat from a bag.
Q. 2
What are the advantages and disadvantages of sampling techniques?
Ans:
Advantages of Work Sampling:
i) Many operations or activities which are impractical or costly to measure by time study can readily be measured by work sampling.
ii) A simultaneous work sampling study of several operators or machines may be made by a single observer.
iii) It usually requires fewer man-hours and costs less to make a work sampling study than it does to make a continuous time study.
iv) Observations may be taken over a period of days or weeks thus reducing the chances of day-to-day variations affecting results.
v) Any interruption during study will not affect the results.
vi) A stop watch is not needed for work sampling studies.
vii) Work sampling studies cause less fatigue and are less tedious.
Disadvantages of Work Sampling :
i) Work sampling is uneconomical for short cycle jobs.
ii) It is also uneconomical for studying a single workman or even small group of workmen or machines.
iii) Time study permits a fines breakdown of activities and delays than is possible with work sampling study.
iv) The operators may not understand value of sample size and accuracy etc.
v) Insufficient observations are likely to produce inaccurate results.
vi) It does not assist in improving work method.
vii) It does not normally account for speed of the operator.
Q. 3
State the complete sampling procedure in terms of various steps?
Ans:
The following steps are usually required in making a work sampling study:
1) Define the problem.
A) State the main objectives or purposes of the project or problem.
B) Describe in detail each element to be measured.
2) Obtain the approval of the supervisor of the department in which the work sampling study is to be made.
3) Determine the desired accuracy of the final results. This may be stated as the standard error of a percentage or desired accuracy. The confidence level should also be stated.
4) Make a preliminary estimate of the percentage occurrence of the activity or delay to be measured.
5) Design the study
A) Determine the number of observations to be made.
B) Determine the number of observers needed.
C) Determine the number of days or shifts needed for the study.
D) Make detailed plans for taking the observations, such as the time and the route to be followed by the observes
E) Design the observation form.
6) Make the observations according to be plan. Analyze and summarize the data.
7) Check the accuracy or precision of the data at the end of the study.
8) Prepare the report and state conclusions. Make recommendations if such are called for.
Q. 4 What is use of control chart in sampling? Explain in details?
Ans:
Control charts have found extensive use in quality control practice. Inspection data obtained at random and plotted on the control chart show graphically whether or not the process is in control.
The control chart in work sampling enables the analyst to plot the daily or the cumulative results of the sampling study. If a plotted point falls outside the control limits this is likely to indicate that some unusual or abnormal condition may have been present during that part of the study. The 3 sigma limit is ordinarily used in determining the upper and lower control limits.
For example, a minor fire in one part of a factory building might disrupt production in the adjoining departments, and the sampling data taken in these areas during the day might therefore show excessive idle time on the part of the operators studied.
The result of a work sampling study of the idle time of the operator of a large press is as shown in fig:
One-hundred observations were made each day for a period of 12 consecutive working days. The data indicate that the operator was idle for a little as 6 percent of the day on December 9, and as much as 23 percent on December 13.
The formula for computing the upper and lower control limits, which are +19 percent and +1 percent respectively, and the control chart for the data.
The control chart is also useful in determining the length of a work sampling study.
Q. 5
Discuss the various applications of work sampling?
Ans:
i) Work of teams has to be investigated.
ii) There is clear distinction between working time and idle time.
iii) To indicate areas of delay.
iv) To investigate and to locate areas under utilization.
v) For establishing over all performance levels.
vi) For determination of machine utilizations.
vii) In determining the distribution of duties among a group of workers.
viii) For the purpose of cost control and accounting.
ix) To estimate allowances for unavoidable delay.
x) In ware housing and shipping operation to pin-point delays.
Q. 6 What do you mean by ‘confidence levels’ in work sampling?
Ans:
The results obtained by work sampling technique differs considerably from the results actually achieved by continuous recording of time. The accuracy of result depends upon the number or observations and the limits of confidence level because the sampling procedure used involves certain degree of error. So it is important to decide, what level of confidence is desired the final ‘Work Sampling’ results.
During a investigation, if we increase the number of observations considerably and in each observation then number of activities are large we can obtain a smoother curve called normal distribution curve as shown in figure:
The most common confidence level is 95%. The area under the curve at 2 sigma or two standard deviations is 95.45% which is rounded off gives 95%. This indicates that the probability is 95% of the time the random, observations will be true or represents the fact and 5% of the time false or will not.
For majority of cases, an accuracy of 5% is considered satisfactory. This is usually referred to as the percentage standard error.
The formula for determining the sample size for a confidence level of 68%, 95% and 99% is :-
Sp = x P (1 – P)
N
Where,
S =
P =
N =
X =
Desired relative accuracy
Percentage expressed as a decimal
number of random observation
1, 2 or 3 for confidence level of 68%, 95% and 99%.
UNIT – V
Q.1
Explain in brief the eight standard work elements mentioned in work factors system?
Ans:
A Work-factor has been defined as the index of the additional time required over and above the basic time. It is a unit for identifying the effect of the variables of manual control and weight.
To analyze the various motions of complete work cycles, the Work Factor System defines certain standard elements of work which are termed as Work Factor Standard Element of work. The Work-Factor system divides into eight “Standard” Elements of Work. These are:
ELEMENT NOTATION
1. Transport (Move and Reach)
2. Grasp
3. Preposition
4. Assemble
5. Use (Process or Machine Time Manual)
6. Disassemble
7. Mental Process
8. Release
TRP
GR
PP
ASY
US
DSY
MP
RL
1.
Transport :
Transport motions are made by the body members in reaching to objects and in moving objects from one location to another.
2.
Grasp:
Grasp is the act of obtaining manual control on one or more objects. It begins at the end of a reach and ends when the control on the object has been obtained. The Work-Factor system recognizes four types of grasp:
§ Simple Grasp
§ Manipulative Grasp
§ Complex Grasp
§ Special Grasp
3.
Preposition:
Preposition is the act of turning and orienting an object to a correct position for a subsequent element of work.
4. Assemble
Assemble occurs whenever two or more objects are joined together, usually through mating or nesting. Assemble also occur when one object is placed in an exact position relative to another. The system provides a complete assemble table. Assemble time depends on:
§ Size of Target
§ Plug Dimensions
§ Plug-Target Ratio
5.
Use:
Use is the act of working with a tool or other device or of using one or more body member as tool. It may also include machine and process time.
6.
Disassemble :
Disassemble is the act of separating objects which have previously been joined together. This element is opposite of Assembly.
7.
Mental Process:
Mental Process applies to all mental activities and processes. It is time interval in which reactions and nerve impulses take place. Mental processes that can be measured include:
§ Eye motions
- Focus
- Shift
- Reactions
§ Inspections
- Quality
- Quantity
- Identify
§ Computations
- Read
- Action
- Concept
8.
Release
Release, the opposite of grasp is the act of a body member separating itself from an object. There are three types:
§ Control Release
§ Gravity Release
§ Unwrap Release
Q. 2
What are the variables in WORK FACTOR system? Explain Work-Factor techniques in brief?
A Work-Factor has been defined as the index of the additional time required over and above the basic time. It is a unit for identifying the effect of the variables of manual control and weight.
The Work-Factor system was one of the first predetermined time systems to have wide general use. The Work Factor system is a set of Motion and Mental Time Tables in which the manual motion and mental
process times are so arranged that an appropriate time can be obtained for a manually controlled motion. The basic principles on which this system depends are as follows:
1) Different body member move at different speeds, depending upon their position in the human body.
2) The time taken to complete a motion by any member is proportional to the distance covered by it.
3) If the movements are with out specific conditions, they take less time. Such motions are known as basic motions.
The Work-Factor system has achieved flexibility by developing different procedures of application, depending on the objectives of the analysis and the accuracy required.
The procedures techniques are known as:
a) Detailed work Factor
b) Simplified Work Factor
c) Abbreviated Work Factor
d) Ready Work Factor
e) Brief Work Factor
f) Detailed men to Factor
(DWF)
(SWF)
(AWF)
(RWF)
(BWF)
(DMF)
Each techniques is self-sufficient, requiring no dependence on a higher or lower level system.
a)
Detailed Work-Factor:
Detailed Work Factor is designed to provide precise time standards for either day work measurement or incentive pay plans. It also provides a precise tool for methods analyses. It is primarily used for short-cycle operations and repetitive work. It is also commonly used for developing standard data. Its Motion Time Table has 764 time values, and it is the most detailed of all modern predetermined motion time systems. It uses a time unit of 0.0001 minute.
b)
Simplified work-Factor:
It is a general higher level system and is suitable for medium quantity production, developed from a Detailed Work-Factor system. It is easier and rapidly used. Time units used in Work Factor table are in ten thousandths of a minute.
c)
Abbreviated Work Factor:
It is a higher level system developed from detailed work factor system and it is especially suitable for small quantity job shops. They provide a rapid measurement procedure. The abbreviated time unit is 0.005 minute.
d)
Ready Work Factor:
This higher level modified work factor system is meant for persons who are not familiar with details of time study techniques. It is generally used for medium quantity production. It has nine elemental descriptions and the Motion Time Table has 154 time values.
e)
Brief Work Factor:
Brief Work Factor Offers the simplest Motion Time, Combining the various standard elements into work segments. It uses a time unit of 0.005 minute. It has five elemental descriptions and its Motion Time Table has only 32 time values.
f)
Detailed Men to Factor :
It is a basic level system which is used for measuring mental processes such as inspection, proof reading colour matching, calculations etc. Its time tables cover 14 fundamental mental processes and have 710 time values.
Work – Factor system recognizes the four major variables that influence the time required to perform a task :
a) The body member making the motion.
b) The distance moved measured in inches.
c) The Manual control required, measured in work factors, defined or dimensional
d) The weight or resistance carried, measured in pounds, converted into Work Factor.
a)
The body member making the motion:
Work factor recognize six definite body members and provides motion times for each.
Body Member Notation
1) Finger or Hand
2) Arm
3) Forearm Swivel
4) Trunk
5) Foot
6) Leg
(F.H)
(A)
(S)
(T)
(FT)
(L)
b)
The distance moved measured in inches:
All distances (except those with change in direction) are measured in straight lines between the starting and stopping points of the motion as described by the body members.
Body Member Point of Measurement
i) Finger-Hand
ii) Arm
iii) Forearm Swivel
iv) Trunk
v) Foot
vi) Leg
Finger tip
Knuckles
Knuckles
Shoulder tip
Toe tip
Ankle bone
All distances are measured in inches.
c)
Weight or Resistance:
The effect of weight on motion time is due to weight of the object handled as well as the need to exert force in order to over come resistance. The effect of weight on time varies with:
i) the body members used
ii) the sex of the operator
d)
Manual Control:
Manual Control is the most complex variable as there is no physical device to measure it. The Work-Factor system classifies the factor of manual control into four types according to their effect on work. They are:
i) Definite stop Work-Factor
ii) Directional control Work-Factor (steer)
iii) Change of Direction Work-Factor
iv) Precaution Work-Factor (core)
Q. 3
Write short note on:
“PREDETERMINED MOTION TIME SYSTEMS” ‘PMTS’
Ans:
A PMTS is a work measurement technique in which times established for basic human motions, are utilized to build up the time for a job at a defined level of performance. This system of time data was originally developed from extensive studies of all aspects of human performance through measurement, evaluation and validation procedures.
PMTS is a work measurement technique and are more refined and accurate than the synthetic times because they are obtained gradually with more and often used as a source of synthetic time data. PMTS are thus more basic in nature than standard data and are more commonly utilized for manual work cycles. The origin of PMTS can be traced to the ‘therbligs’ and the first attempt to ascertain time by motion length as done by Gilbreth in chronocyclograph. Therbligs has been used as basic motion units in all PMTS.
Some factors to be considered in Using a PMTS:
i) Application of PMTS requires that an operation which is to be measured is divided into basic motions as per the system selected.
ii) Most PMTS do not include allowances, so these are added as in stop watch study.
iii) PMTS can be classified as to accuracy level, time required for application and the extent of method description.
The predetermined time systems has been successfully applied to :
i) Determine job time standards.
ii) To estimate the manpower, equipment and space requirement before production or prior to setting up of facilities,
iii) For improving and modifying work methods before stating the work on the job.
iv) To set time standards for various jobs.
v) To provide a basis for estimation of labour cost and wage plans.
vi) To facilitate training of the workers and supervisory staff.
The most commonly used PMT systems are:
i) Work Factor (WF)
ii) Method Time Measurement (MTM)
iii) Basic Motion Time study (BMT)
iv) Dimension Motion Time (DMT)
(1938)
(1948)
(1951)
(1954)
The main uses of predetermined time systems may be divided into the following two classes:
Uses in Work Methods:
i) Improving existing methods.
ii) Aiding in the design of the product.
iii) Aiding in training operators.
iv) Evaluating proposed methods in advance of actual production.
v) Evaluating suggested designs of tools, jigs and equipment.
vi) Training members of the staff to become motion minded.
Uses in work Measurement:
i) Establishing time standards.
ii) Compilation of standard data and formulas for specific classes of work.
iii) Checking standards established by time study.
iv) Auditing time standards.
v) Estimating labour costs.
vi) Balancing production lines.
Advantages of PMTS:
i) No timing is required so it eliminates in accuracies associated with stop watch time study.
ii) Rating, the most difficult part of time study is not necessary.
iii) The results obtained are consistent.
iv) Time standard for a job can be arrived at without going to the work place.
v) The time and cost associated with finding the standard time for a job I considerably reduced.
Limitations of PMTS:
i) PMTS can deal manual motions of an operation only.
ii) They are not economical for non repetitive operations.
iii) They can not be applied to restricted work.
iv) All categories of motions have not been taken into consideration while collecting PMTS data.
v) The need of trained personnel. PMT system eliminates the utilization of rating.
Q. 4
Briefly describe MTM system?
Ans:
The Method-Time Measurement (MTM) system of predetermined time standards was developed from motion picture studies of industrial operation, and the time standers were first published in 1948. This system is defined as a procedure which analyzes any manual operation or method into the basic motions required to perform it, and assigns to each motion a predetermined time standard which is determined by the nature of the motion and the conditions under which it is made.
Beginning is 1963 the first new member of the MTM< system called General Purpose Data (MTM-GPD) was introduced and at that time MTM-1 was used to designate the original basic MTM system. Today, the family of systems includes MTM-1, MTM-GPD, MTM-2, MTM-3, MTM-V, MTM-M, MTM-C and 4M DATA.
Unit of MTM is TMU:
One TMU = 0.0000 1 hour
One TMU = 0.0006 minute
One TMU = 0.036 second
Uses of MTM :
i) Developing effective methods and plans in advance of beginning production.
ii) Improving existing methods.
iii) Establishing time standards.
iv) Cost estimating.
v) Training supervisors to become method conscious.
vi) Research in the areas like operating methods, performance rating.
MTM Procedure recognizes :
A) Eight Manual movements.
B) Nine pedal and trunk movements.
C) Two ocular movement
A)
Eight manual movements :
i) Reach
ii) Move
iii) Apply Pressure
iv) Turn
v) Grasp
vi) Position
vii) Disengage
viii) Release
B)
Nine pedal and trunk movements:
i) Side step
ii) Turn Body
iii) Walk
iv) Bend
v) Stoop
vi) Kneel on One Leg
vii) Kneel on Both Leg
viii) Foot Motions
ix) Sit
Thus there are nineteen fundamental motions to be considered in the establishment of any motion pattern. The time for a given motion is affected by a combination of physical and mental conditions.
Q. 5
Define the following:
1) MTM – 1
2) MTM – 2
3) MTM – 3
Ans:
1) MTM – 1
MTM-1 is the most accurate. Provides the most detailed method detailed description but requires the longest time for analysis. This table provide the motion time data for each basic element. The unit of time used in these tables is one hundred-thousandth of an hour (0.00001 hour), and is referred as one time measurement unit (TMU).
Thus,
One TMU =
=
0.0006 minutes
0.036 sec.
2) MTM – 2
MTM-2 was developed by constructing motion combinations from basic motions of MTM -1. It has a smaller number of distance ranges and fewer cases of control than MTM-1. The analysis can be made more quickly than with MTM-1, accuracy and method descriptions are not as great. MTM-2 is suitable for work that is not highly repetitive and for elements that are not less than 1 minute long. The system consists of nine categories of manual motions:
Motion Symbol
1) Get
2) Put
3) Apply Pressure
4) Regrasp
5) Eye Action
6) Crank
7) Step
8) Foot Motion
9) Bend and Arise
G
P
A
R
E
C
S
F
B
The combination system and application decision is such that MTM-2 analyses are within + 5 percent with 95 percent confidence level from MTM-1 with cycles of 1 minute or more. Speed of analysis with MTM – 2 is twice as fast as with MTM – 1. The following figure shows the percentage variation of MTM – 1 when compared with MTM – 2 at increasing cycle lengths.
3) MTM – 3:
MTM 3 is the simplest of the MTM systems and is intended for use with long-cycle short-tun operations. It should not be used for analyzing manual motions with a frequency higher than 10 or sequence of eye motions. The MTM – 3 system consists of four categories of motions:
Motion Symbol
1) Handle
2) Transport
3) Step and Foot motion
4) Bend and Arise
H
T
SF
B
Speed of analysis with MTM – 3 is seven times as fast as with MTM – 1 and three times as fast as with MTM – 2.
MTM – 3 should not be used for analyzing manual motions with a frequency higher than 10 or a sequence of eye movements.
MTM – 3 has been computerized and utilizes a data collection instrument and desk-top computer.
Q. 6
In MTM system, state and discuss the basic manual motion ?
Ans:
The eight basic manual motions are as follows :
1) Reach
2) Move
3) Apply Pressure
4) Turn
5) Grasp
6) Position
7) Disengage
8) Release
1)
Reach
Reach is the basic element used when the predominant purpose of the motion is to move the hand or fingers to a definite destination. The time to perform a reach is affected by the nature of the object toward which the reach is made.
There are five classes of reach:
§ Case a reach :
To object in fixed location or to object in other hand, or on which other hand rests.
§ Case B reach :
To object whose general location is known. Location may very slightly from cycle to cycle.
§ Case C reach :
To objects jumbled with other objects in group.
§ Case D reach :
To very small object or where accurate grasp is required.
§ Case E reach :
To indefinite location to get hand into position for body balance or next move or out of the way.
The length of a motion is the true path, not just the straight-line distance between the two terminal points.
There are three types of reach to be considered :
1) Hand is not moving at beginning and at end of each.
2) Hand is moving at either beginning or end of reach.
3) Hand is in motion at both beginning and end of reach.
2)
Move :
Move is the basic element employed when the predominant purpose is to transport an object to a destination.
There are three classes of moves.
§ Case A move :
§ Case B move :
§ Case C move :
Object to other hand or against stop.
Object to approximate or indefinite location.
Object to exact location.
The time for move is affected by the following variables:
1) Condition (nature of destination)
2) Length of the motion.
3) Type of move.
4) Weight factor, static and dynamic.
3)
Apply Pressure:
It is a basic element used to overcome resistance or to have exact control on the object. Two types of apply pressure are usually observed in industrial activity. There are :
§ Apply Pressure Case A :
Application of pressure only. This would naturally require less time than B.
§ Apply Pressure Case B :
Regrasp or sequeoge and apply pressure. It needs precision which is more than normal.
4)
Turn:
Turn is defined as the motion used to rotate the hand about the long axis of the forearm. The time for a turn depends on two variables:
§ degrees turned
§ weight factor
6)
Position :
Position is the basic element employed to either align orient or engage on object with another object. There are three variables affecting position:
1) Class of fit
2) Symmetry
3) Ease of handling
7)
Disengage:
Disengage is the basic element used to break contact between one object and another. The objects are separated away. Disengage times depend upon:
1) Class of fit.
2) Ease of handling.
3) Care in handling.
8)
Release:
Release is the basic element to relinquish control of an object by the fingers of hand. The two classifications of release are:
1) Normal release, simple opening of fingers.
2) Contact release, the release begins and is completed at the instant the following reach begins (no time allowed).
Q. 7
Explain the following terms:
i)
RL1
ii)
RL2
iii)
PINSD
iv)
P2NSD
v)
P2SSE
vi)
P1SE
vii)
T3OS
viii)
T9OL
ix) R4A
x)
R8C
xi) R1OC
xii)
R12Am
xii)
M10B15
xiv)
M16B15
xv)
M16Am
xvi)
M6A
xvii)
MM1OC
xviii)
G1A
xix)
G2A
xx)
G3A
xxi) G4A
xxii)
ET 14/10
Ans:
i) RL1 :
Releasing the object by opening the fingers.
ii) RL2 :
Contact release, no time is allowed for executing this motion.
iii) P1NSD :
Position, class 1. Fit, non-symmetrical and difficult to handle.
iv) P2NSD :
Position, class 2 fit, non-symmetrical and difficult to handle.
v) P2SSE :
Position, class 2. Fit, semi symmetrical, and easy to handle.
vi) P1SE :
Position, class 1. Fit, symmetrical, and easy handle.
vii) T3OS :
Turn 30 small load
viii) T90L:
Turn 90° load more than 35 lb.
ix) R4A :
Reach, 4 inches, Case A
x) R8C :
Reach, 8 inches, Case C
xi) R10C:
Reach, 10 inches, Case C
xii) R12Am :
Reach 12 inches, Case A, hand in motion.
xiii) M10B15 :
Move, 10 inches, Case B, object weights 15 lb.
xiv) M16B15 :
Move, 16 inches, Case B, object weights 15 lb.
xv) M16 Am :
Move 16 inches, Case A, hand in motion in beginning or end (weight is less than 2.5 lb)
xvi) M6A :
Move 6 inches, case A, object weight less than 2.5 lb.
xvii) mM10C :
Move 10 inches, Case C hand in motion at beginning object weight less than 2.5 lb.
xviii) G1A :
Simple closing of fingers to secure control of a single object.
xix) G2A :
Regrasp or shifting of an object in hand to get better control.
xx) G3A :
Changing control of an object from one hand to another hand.
xxi) G4A :
Usually used for sliding, Hook, contact, Grasp etc.
xxii) ET14/10 :
Eye travel between points 14 inches apart where line of travel is 10 inches from eyes.
UNIT – VI
Q. 1
Write short note on :
“Standard data”
Ans:
Standard data is a form of work measurement that consists of time values for specific elements of work. The manual part of a task is broken down into groups of hand motions or body movements that can be precisely defined and that are applied only in connection with a particular machine or a specific operation. The elemental time values usually take the form of tables, formulas, or graphs. Elemental time values for establishing standard data had been determined by stop-watch time study until predetermined time systems became available. Predetermined times have some important advantages over times study but the detailed motion analysis is very time consuming. However, through a simple plan for combining motions into elemental building blocks and the further combination of these data, Deere and Company has developed system of ‘Operational Data’ which they have used success fully over a period of years. Some 700 different sets of data have been developed covering 250 separate manufacturing processes. The areas covered by these data include foundry, forge shop, punching, forming, shearing, welding, painting, assembly, shipping etc. 80% of all incentive standards in their domestic plants are established by their Operational Data. 50% of all factory employees are paid on an incentive basis.
Advantages of Standard Data :
1) It estimates performance rating when determining time standards.
2) It permits establishing standards in advance of actual production.
3) It permits standards to be established rapidly and inexpensively.
Disadvantages of Standard Data:
1) It may not accommodate small variation in method.
2) It is more difficult to explain to workers than in stopwatch procedure.
3) It may cost too much to develop standard data.
Q. 2
What is multi-factor incentive plan? How it can be applied to transfer machine operation? Discuss the advantages of multi-factor Wage Incentive system?
Ans:
In some industries labour costs are small in comparison with operating costs of machines and process equipment. The ideal incentive plan for the operator of costly machines and process equipment night be a multi-factor play. For example a plan might be designed to include such factors as square feet of material processed, percentage of product of acceptable quality product, and utilization of material. As industry becomes more highly mechanized, greater attention will be paid to those factors that make for
low operating costs of the equipment. The goal will be lower unit cost of the end product rather than low direct labour costs alone.
It is possible to measure the effectiveness of each of the major factors affecting the cost of a manufactured product. Machine and equipment utilization and material utilization are of special concern in many organizations. An index number can be provided to indicate performance that is its effectiveness or utilization. The two factors in the equation for determining the equipment utilization index are :
1) The output or the number of good pieces produced per day.
2) The maximum capacity of the equipment or the total number of pieces that could be produced per day.
For the bottle filling operation the equipment utilization index would be :
Equipment Utilization Index: Actual number of bottles filled during day x 100 numbers of bottles that a could be filled if the m/c ran at maximum capacity during the day.
In the manufacture of tennis shoes the utilization index for the insoles cut from sheets of gum fabric would be:
Material
Utilization Index =
Total area in square inches of all parts
cut from fabric during day
x 100
Total area in square inches of fabric
passing through the press during the day
In a similar manner ratios can be determined for other cost factors.
The Buhr transfer line for machining the two major aluminum parts for the gear case of an automatic clothes washer and for the assembly of two bushings and three stud shafts. The machine has II separate transfer stations. 65 cutting tools, five hopper feeders for the shafts and bushings, and an in-line wash booth. One gear housing and one top cover are mounted or a transfer pallet and are machined together. The bushings and pins are inserted and pressed into place at stations 9 and 10. Two workers are needed to operate the machine. One operator loads and unloads the two parts and performs the necessary inspection. A second operator checks the finished parts for porosity in a separate machine and places them on the conveyor. Both operators work together to make tool changes and adjustments, or to correct minor problems causing machine stoppages.
The Buhr transfer line was the first one placed on incentive. This plan provided operator earnings comparable with those attained on jobs where the standard hour plan was used. It also resulted in substantially higher productivity, improved quality, and lower overall operating costs than could be expected had the plan not been installed.
Multi-factor incentives have been applied only to mechanized equipment installation at Maytag. The principle of paying incentive premiums for specified measurable and results that are economically important and which can be influenced by operators, can also be applied to other work situations.
Q. 3
Write short note on:
“Necessity of Training Programs”
Ans:
Training means educating a worker in basic and technical skills. It also includes assessing the talent in a worker and giving him such knowledge, which broadens his skill. The training in simple word means development and education. In classifying the training we will have to take care of assessment of the need of training and different methods of trainings.
There are four ways that determine the training needs of organization
1) Performance appraisal
2) Analysis of job requirement
3) Organizational analysis
4) Survey of personnel.
Some characteristics of successful training programs are :
1) A well-qualified instructor with an ability to teach well.
2) A detailed timetable of instruction that is followed.
3) Adequate physical facilities that allow instruction without disturbing interruptions.
4) An atmosphere that allows students to make mistakes and to learn corrections.
5) A follow-up routine to reinforce learning and confidence.
The need of training arises due to the following:
1) When a new employee joins the organization needs training to be familiar with the job, colleagues at the workplace rules and regulation of the company.
2) To maintenance high morale of the employees training becomes essential.
3) Training increases productivity and reduces cost, as it reduces learning time, waste of raw material.
4) Safe working is best working. Training reduces accidents.
5) To have additional hands for increasing production, training is needed.
6) Remedial training is given to the employees to teach than right way of doing work to avoid wastages.
7) Training helps promote employees to higher level hence development in the career.
The different methods of training can be divided into two categories:
a) On-job training
b) Off-job training
a)
On-job training :
Workers is given training at the workplace under this method. It is normally given in the premises of the industry itself.
They includes :
1) Coaching
2) Job rotation
3) Under study
4) Special project
b)
Off-job training :
It removes individuals from worries of workplace so that the worker can concentrate fully for learning the techniques.
They includes:
1) Vestibule training
2) Class room instruction
3) Seminar and Conference
4) Committee assignment
5) Role playing
Training is an investment. It accurse many benefits to the company.
1) Better performance
2) Uniformity of procedures
3) Economy in use of material and equipments
4) Less supervision
5) High Morale
6) Better Management
7) Fill manpower needs.
Q. 4
Write short note on:
“Computer Application in Work Study”
