Methods engineering /work design

Breakdown of operation into components

Systematic analysis of each component

Eliminates un-necessary operations

According to BSI It is systematic recording & examination of existing

methods of doing work and developing more effective

methods”

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SELECT

RECORD

EXAMINE

DEVELOPE

EVALUATE

DEFINE

INSTALL

MAINTAIN

Procedure for

Method Study

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Recording techniques for Method Study

Charts

Macro Motion charts

1.Operations Process Chart

2.Flow Process Chart

3.Two Handed Process Chart

4.Multiplle Activity Chart

Micro Motion charts

SIMO Chart

Diagrams

1.Flow Diagram

2.String Diagram

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OPERATION

INSPECTION

TRANSPORTATION

DELAY

STORAGE

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1.Operation Process Chart

•Also called Outline process chart

•Bird’s eye view of whole process

•Records only major activities and inspections

•Uses only two symbols i.e. operations & inspection

•Constructed by placing symbols one below another

Uses

•Visualize sequence of operations & inspections in process

•Know where operations selected fits into the entire process

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2. Flow Process Chart

• Gives sequence of flow of work

• Operations, inspection, storage, delay and transportation are

represented

• Constructed same as operation process chart

• Three types

1. Material type

2. Man type

3. Equipment type

Uses

•Reduce idle time and delays

•Reduce distance travelled

•Reduce production cycle time

•To relocate inspection stages

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Distance in

meter

Symbol Process description

10 Move to cabinet

- Get loaf of bread

- Remove two slices of bread

- Lay slices on table top

- Close loaf of bread

- Replace loaf on shelf

- Open butter

- Spread butter on top slice

- Inspect sandwich

- Move to serving area

10 Serve sandwich

Process chart for making a cheese sandwich

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3.Two handed process chart

•Most detailed type

•Activities of workers hand recorded in relation to one another

•Confined to work carried out at a single workplace

Uses

•Visualize complete sequence of activities in repetitive task

•Study work station layout

4.Multiple activity chart

•Activities of more than one subject each recorded

•Common time scale to show inter-relationship

Uses

•Study idle time

•Determine no. of machines handled by one operator

•Determine no. of operators required

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Time Operator Machine 1

Washer

Machine 2

Dryer

# Sec Load clothes & detergent

in machine 1

Being loaded Idle

idle Run Idle

- Remove clothes from

machine 1

Being unloaded Idle

- Load clothes into machine

2

Idle Being loaded

- Load clothes & detergent

into machine 1

Being loaded Run

- Idle Run Run

- Remove clothes from

machine 2

Idle Being unloaded

- Hang clothes Idle Idle

Multiple activity chart for doing three loads of laundry

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1.Flow diagram

•Drawing of working area & showing location of various activities

•Shows the route followed and selects the optimum one

•Study different layout and selecting optimum one

•Study traffic and frequency over different routes

Procedure :

•Layout of workplace is drawn to scale

•Relative positions of the m/c tools, storage & inspection benches

are marked on the scale

•Path followed by the subject under study is tracked by drawing

lines

•Each movement is serially numbered & indicated by arrow for

direction

•Different colors are used to denote different types of movements

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1.String diagram

•Scale layout drawing

•length of a string is used to record extent & pattern of movements

of a worker within a limited area.

•Movements difficult to trace on flow diagram can be shown

•Shows the route followed and selects the optimum one

•Study different layout and selecting optimum one

•Study traffic and frequency over different routes

Procedure :

•A Layout of workplace is drawn to scale

•Pins are fixed into boards to mark locations of workstations

•Pins are also driven at turning points of the routes

•A measured length of thread is taken to trace the movements

•The distance covered by object is obtained by measuring the

remaining part of the thread and subtracting it from original length

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•Suggested by Frank o Gilbreth

•Technique for recording and timing an activity

•Divides human activities in a group of movements or micro

motions (called therblings)

•Helps to find best pattern of movements for an operator that

consumes less time and requires less effort

Steps involved

•Filming the operation to be studied

•Analysis of the data from the film

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Sr. Code Name Description Colour

1. SH SEARCH Locate an article Black

2. G GRASP Taking Hold Red

3. H HOLD Prolonged grasp Gold

ochre

4. A ASSEMBLE Putting parts

together

Violet

5. DA DIS-

ASSEMBLE

Separating parts Light violet

6. U USE Causing a device

to perform its

function

Purple

7. R REST Pause to

overcome fatigue

Orange

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Therblings

•SIMO = SImultaneous MOtion Chart

•Recording technique for Micro Motion study

•Simultaneous motions are filmed and recorded on a common

time scale and analyzed

•Therblings performed by different parts of body of one or more

operators recorded

•Expensive equipments required

• used when saving from study is high

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THANK YOU