WORK MEASUREMENT KNOWLEDGE SHARING:

Time Study Basics and Timer Pro Basics

References:- Work Study – International Labor Office Geneva- Industrial Engineering Handbook - Maynard- Doc. No. PR001B-

http://dis.schneider-electric.com/Global/DDi/DIS/EN/SiteMgr.nsf/Homepage?ReadForm

Albert Serote | APC by Schneider Electric | IT Business | PH Industrial Engineer

To gain common understanding on the way P1F conducts time study.

To be able to establish, maintain, and update XMN Manufaturing Standard Time.

To be able to use basic Timer Pro operation for time study.

OBJECTIVES

TIME STUDY BASICS

HOW TO CONDUCT TIME STUDY

VIDEO ANALYSIS TOOL: TIMER PRO

OTHER CLARIFICATIONS

TOPICS

Time Study Basics…

is a method of recording the times for the elements of a specified job carried our under specified conditions, and for analyzing the data so as to obtain the time necessary for carrying out the job at a define level of performance.

WHAT IS TIME STUDY?<

The choice of the methodology will depend mainly on:

- the operation cycle time- the volume of identical or similar parts or products manufactured

- Self recording, Compare-Estimate, Activity sampling, Stopwatch time study and Video-analysis are retrospective methods in that the jobs must be seen- Micro or Macro Standards are prospective methods as they can be used for timing jobs before they start.

The “method level” (Micro-standard to Macro-standard) will depend on the operation cycle time and repetitiveness:

- the method level is the quality of a work routine dependent upon the skill of the respective individual and the organizational degree of the work system.

Part of the method that cannot be described by the analysis

Part of the method that can be described by the analysis

CompleteWork method

Analyzablemethod level

Uncontrolledmethod level

Part of the method that cannot be described by the analysis

Part of the method that can be described by the analysis

CompleteWork method

Analyzablemethod level

Uncontrolledmethod level

Work measurement techniques

Methods Measurement Main carateristics Accuracy / confidence Useful forSelf recording From production tracking No identification of VA / NVA Product families definition in ETOCompare - Estimate From historical data Mostly subjective Product families definition in ETOActivity sampling Observation on random intervals Large number of observation Non repetitive & long cycle timeSopwatch time study Timing & performance rating Pace rating system required Mass production & short cycle timeVideo analysis Sequence timing from video Equipment & software required Standards/operation definitionMicro-standard data Motions standards data (ex. MTM) Predetermined time system Mass production & short cycle timeMacro-standard data Operations standards data (ex. UAS-2) Predetermined time system Batch production & long cycle time

Engineered To OrderProcesses

Pre-engineered ProductsProcesses

High method

level

Lowmethod

level

Self recording : time noted on product or work-order tracking sheet- useful for efficiency tracking, assessing work and to group similar products/processes into families- not recommended to develop standard times

Compare – Estimate : time noted from comparison of similar product or process or estimated by the analyst from knowledge and practical experience of work

- useful for efficiency tracking, assessing work and to group similar products/processes into families- not recommended to develop standard times

Activity sampling : time noted from statistical technique that can be used as a means for collecting data. A technique in which a large number of observations are made over a period of time of processes or workers, the statistical error depends on the size of the sample.

- not recommended unless there is no other method available at the time

Stopwatch time study : the observer time each element and each timing is rated by the pace at which the operator was working. It is subjective, not reproducible, has a low confidence and one needs a long time for training.

- could be useful for standard time definition in running production but require well trained engineers- not recommended unless there is no other method available at the time

Video-analysis : time noted from video recording of work method using computerized study board. - could useful to create macro-standard data when used with a rating system and when products are produced on an infrequent basis- recommended for Make to Order or for Engineered To Order products

Micro-standard data : predetermined motion time system as Method Time Measurement. Effective for developing standards for highly repetitive tasks that have relatively short cycle time.

- recommended for pre-engineered products in batch or mass production

Macro-standard data : describe the time data for a compilation of group of motions. They take advantage of similarities of activities within like families of operations and uses those similarities to develop standards for related activities.

- recommended for Make to Order or for Engineered To Order products

Work measurement techniques

TWO METHODS OF TIMING

Fly back or snap back timing - the timer is returned to zero at the end of

each element and are allowed to start immediately for the following element. This is generally used for all time studies.

Cumulative timing - the timer runs continuously throughout the study. It is started at the beginning of the first element of the first cycle to be timed and is not stopped until the whole study is completed. The individual element times are obtained by successive subtractions of the time for each element after the study is completed. This method is generally used to ensure that all the time during which the job is observed is recorded in the study. However, this includes non-standard activities, elements, downtimes, and un-necessary movements of the operator.

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THE “ELEMENT”

is a distinct part of a complete work cycle of a specified job selected for convenience of observation, measurement, and analysis.

Work Cycle - is the sequence of elements, which are required to perform a job.

TYPES OF ELEMENTS

Repetitive element - occurs repetitively in every work cycle of the job.Example: screwing, insert, paint marker, rivet Occassional/incidental element - occurs occassionally in every work cycle of the job at regular or irregular interval.Example: Fill-up ticket, attach sticker Constant element – basic time remains constant whenever it is performed.Example: Burn-in time, cure time Variable element - basic times varies in relation to some characteristics of the product, equipment, or process.Example: External visual inspection Manual element - element performed by a workerExample: Fill-up ticket, get lot, load wafer.SPS TERM: Tm – manual time Machine element - element automatically performed by a machineExample: Burn-in , screen printSPS TERM: Tt – technological timeMan-Machine element – semi-automatically performed by a machine, but with the aid of a workerExample: Manual Test, forklift operationSPS TERM: Ttm – techno-manual time Foreign element - element observed during the study which, after the analysis, is not found to be necessary part of the job.

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CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS

CONDITIONS AND CONSIDERATIONS<

The standard time is the time required by an average skill worker, working at a normal pace, to perform a specific task using a prescribe method, allowing time for personal needs, fatigue and delay.

Time standards are always related to work standards & work instructions.

An average skill worker is an operator who is representative of the people performing the task, someone who is skilled in the job and can perform it consistently throughout the entire day.

The normal pace is a rate of work that can be maintained for an entire work day.

MANUFACTURING STANDARD TIME<

How to conduct Time Study…

DATA GATHERING - Gather all information for the part number or stock keeping units (SKU) to be studied. This

should be use as the basis and initial information on the product specifications and availability status.

SELECT APPROPRIATE JOB CONDITIONS- Only qualified operators should be studied. This operator should have sufficient training,

education and demonstrated level of skill and effort to perform at an acceptable level with respect to both quantity and quality.

Only qualified operators should be studied. This operator should have sufficient training, education and demonstrated level of skill and effort to perform at an acceptable level with respect to both quantity and quality.-Machines should be qualified and working according to its function.-Process should have been established and documented thru acceptable, understandable, and approved work instructions.-Materials are readily available and qualified for the operation.-Acceptable layout, fixtures, and tools ready for use.

CONDUCTING THE TIME STUDY

SELECTING THE TIME STUDY TECHNIQUE- Techniques are chosen based on company requirement, applicability, urgency, and general

purpose.

STUDY THE PROCESS- One should familiarize himself to the process, sequence, and location of the Job in order to

do the time study.

BREAKDOWN OPERATION INTO “ELEMENTS”- Operation should be broken down into elements, in this way, certain purposes could be

accomplished as a result of a well broken down operation. As such purposes are, lean classification, line balancing, improvements, comparison, and a well understanding of the details for those who would be succeding to continue or maintain the time study itself.

CONDUCTING THE TIME STUDY

DECIDING ON THE “ELEMENTS”-Work elements selected should correspond to a standard work method that has beenrunning smoothly for a period of time in standard work environment.-Elements should be easily identifiable, with definite beginnings and endings known as "breakpoint".-Elements should be as short as can be conveniently timed by the observer, generally considered to be about 2.4 seconds.-Incidental operations should be identified and separated from the repetitive work.-Should be identifiable for lean classification (VA, CNVA, FNVA, Tt, Tm, Ttm)

SAMPLE SIZE-Number of observations sample size can be reduced if practical trend of time were observed and established.

CONDUCTING THE TIME STUDY

SETTING THE STANDARDS

NORMAL TIME is the time it would take by a qualified worker to carry out the element at standard rating or at normal pace.

NORMAL TIME = AVE. OBSERVATION TIMES X RATING FACTOR

STANDARD TIME is the time required by an average skill worker, working at a normal pace, to perform a specific task using a prescribe method, allowing time for personal needs, fatigue and delay.

FREQUENCY is the number of occurrence of a specific element in every work cycle (every lot) of the operation.

PFD ALLOWANCE is personal, fatigue, and delay allowance. We use the International Labor Office table for reference.

STANDARDS = NORMAL TIME X FREQUENCY X PRD ALLOWANCE

SETTING THE STANDARDS<

Good practice in Video-analyze

By Viswanathan Muthuraman method engineer & Ashish AdhikariHead - Operational Excellence – APC Bangalore

Work load Analysis : -

No. of SKU’s - 400 Finished Goods + 500 PCB’s for this many unit the time study has to be done

When any process change or improvement is happening, as the time study is manual, we have to repeat the whole time study again.This makes the process cumbersome.This initiated to search for an alternate option.

The objective is, using the alternative option the IE Engineer should be able to do the study from his table and all other calculations should be automatic and line balancing should be done using drag and drop method. When an improvement is happening only that element / process should be able to modify

Effect of process changes & Improvements : -

Alternate Option selected was to do a Video Time study using a software including video and time measurement

Details of Video Time study Software

Name of the Software : Timer ProSoftware owner : ACSCOWebsite : www.acsco.com

Analyzing process in Software, main controls

Video Display

Data collected

Video play control & info

Snap shot capture

Activity list

File control

Activity description

Sample Reports – Stage Summary report

Sample Reports – Line balance reports

More options are available for analysis

Line balancing

Pareto

Ergonomics

VA / NVA

Allowances

Final standard report<

3 – Added Value / Non Added Value identification

Schneider Production System

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Pre-engineered products are standard product and sub-assembly displayed in the Schneider catalogue

The manufacturing operations are repeated few times a day, The assembly learning time is quite short and the operator should not have to refer to specifications every cycle.

Are considered as increasing the product value: all elements or motions done within the comfort or acceptable ergonomic zones as defined in the Schneider ergonomic handbook, and concerning the following operations :

manual or assisted assembly.

adjustment and electrical or mechanical normative test

labeling and customer packaging before shipmentThe issuer of the order is considered as the customer of the line

Added Value for "Pre-Engineered Product"

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Tasks not included in the Useful Time and considered to have no added value:

Every hand motion outside of the ergonomic zones as defined in the Schneider ergonomic handbook.

Each time an operator walks out the “U” shape line (procurement, evacuation, etc.).

Each time an operator moves from one workstation to an other one

Visual inspection for compliance, operating inspection (requested by the designer), and auto-inspection (Compliance inspection is a specific action to check whether the assembly has been carried out correctly).

Reading drawings or filling out administrative documents (start-up, recording, etc.).

Tasks associated with work organisation (co-ordination, change over time, inventories, work station cleaning, maintenance, etc.)

Frequential elements, re-packing and labelling of parts required by the process

Quality actions (sorting parts, treating rejects, repairs, etc.).

Operator waiting time

Physiological resting time

Non-Added Value for "Pre-Engineered Product"

• Elasticity is required , because the line capacity should be rapidly adjusted to the variation in the customer orders received. Sometime the operators should move from one workstation to an other one, the time spent is not included in the Useful Time calculation.

• Useful time is calculated for a defined process. If the process is in the middle of being re-engineered, the useful time is calculated for the new process organisation. Do not define a Useful Time based on potential improvements but only on real commitments

(action plan, investments, deadlines for its implementation).

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The following inspections are considered as normative and value added:

Inspection carried out according to the product norms (CEI, UL, NEMA …). Example : low voltage or high voltage insulation test

Operating inspection : running test designed and applied according to the customer requirements. Example : test of the product driver circuit according to the customer requirements

Those operating times are included in the Useful Time calculation

Inspections which are considered to have no added value:

Visual inspection for compliance and auto-inspection

(Compliance inspection is a specific action aimed at checking to see whether the assembly or the customer order has been carried out correctly).

Operating inspection for internal processes requested by: - Marketing

- R & D

- Advanced manufacturing

Normative Inspection

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Industrial Efficiency IE = Useful Time / Time spent

UsefulTime

Tim

e

Sp

en

t

DVC services

Uncertainties

NonQuality

Pa

id

ho

urs

absenteeism

DCVexternal to

process

Frequentialelements

Operator

activity

Cyclicelements

Non value added characteristic of the

process design

Waste generated by running the process

Theoretical breakdown of manufacturing labor time

Diff

eren

ce =

TS

- U

T

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Pre-engineered products:

- Value-added manual assembly operations- Motions inside of the ergonomic zone (parts or tools) (see slide 28 & 29)- Normative controls or controls required by customer- Packaging before shipment

Engineered-To-Order products :

- same definitions than pre-engineered product- + reading drawings or documentation useful for the product assembly- + fill in administrative document to be sent to customer- + picking and packaging parcel to be sent to customer

Theoretical breakdown of manufacturing labor time

Cyclic

non VA

Frequential

non VA

Operator

Activity

DVC External to

Process

Non

Quality UncertaintiesUseful

Time

Cyclic

non VA

Frequential

non VA

Operator

Activity

DVC External to

Process

Non

Quality UncertaintiesUseful

Time

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Cyclic elements (sequential actions proportional to the volume) :

- Motions outside of the ergonomic zone (see slide 28 & 29)- Moving outside of the working zone (procurement, taking parts from the line,

…)- Quality non-normative control, visual control included in the PQCP.- Non value-added cyclic element or operation- Cyclic administrative task conducted by direct workers- Operating waiting time - Physiological rest

Frequential elements (sequential actions proportional to "n" cycles) :

- Procurement or removal of products or parts- Sampling quality control - Batch label printing- Non value-added sequential element or operation- Non cyclic administrative task conducted by direct workers

Theoretical breakdown of manufacturing labor time

Cyclic

non VA

Frequential

non VA

Operator

Activity

DVC External to

Process

Non

Quality UncertaintiesUseful

Time

Cyclic

non VA

Frequential

non VA

Operator

Activity

DVC External to

Process

Non

Quality UncertaintiesUseful

Time

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Value added Zone for Pre-engineered products assembly

1170 maximum( 46’’)

290( 11’’)

90

250 ( 10’’)250 ( 10’’)

Comfort zoneComfort zone 2-hand zone

100 ( 4’’)

Arduous zone

Acceptable zone Acceptable zone

Green zones (acceptable & comfort zone) are considered as Value Added Zone

Value Added Zone for ETO processes

Product

Value Added Zone

80cm 80cm80cm80cm

Par

tsP

arts

Value Added Zone for ETO processes

Comfortzone

1500( 59’’)

800( 32’’)

1600( 63’’)

Acceptablezone

Arduouszone

Arduouszone

Green zones (acceptable & comfort zone) are considered as Value Added Zone

THANK YOU VERY MUCH…