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Work Measurement Methods: Jobs, Innovation, Growth, Stability WWW - Ies.ncsu - Edu
Work Measurement Methods: Jobs, Innovation, Growth, Stability WWW - Ies.ncsu - Edu
Haleh Byrne
Product Lead – Industrial Engineering
North Carolina State University
Industrial Extension Service
Campus Box 7902
Raleigh, NC 27695-7902
1-800-227-0264
Jobs, Innovation, Growth, Stability www.ies.ncsu.edu
“If you’re not keeping
score, you are just
practicing.” - Vince Lombardi
2
WHAT IS WORK MEASUREMENT?
Systematic determination of the amount of effective physical and mental work in terms of work units in a
specified task.
3
General Steps in Work Measurement
Measure Work
4
WHERE DO WE USE TIME STANDARDS?
Product Costing
Delivery
5
WHERE DO WE USE TIME STANDARDS?
Capacity Analysis
6
WHERE DO WE USE TIME STANDARDS?
System Simulation
7
WHERE DO WE USE TIME STANDARDS?
Labor Requirements
8
WHERE DO WE USE TIME STANDARDS?
Benchmarking
9
WHERE DO WE USE TIME STANDARDS?
10
• UNPREDICTABLE
TIME
LACK OF • UNPREDICTABLE
RESULTS
CORRECT • INEFFICIENT
STANDARD ALLOCATION OF
RESOURCES
TIMES • INACCURATE
OPERATION COST
ESTIMATES
11
The Whole Picture
Improved
Production
Planning &
Scheduling
Reduction
Increased of excess
capability to adapt inventory
customer demand
Reduction of
manufacturing
cost
13
Engineering & Lean Six Sigma Approach
PDSA Cycle
14
PDSA
Engineering & Lean Six Sigma Approach
for Work Measurement
IDENTIFY SCOPE
MODULES MEASURE
D
O
dy
A
C
t u
T
S
ASSESS AND
COMMUNICATE
OPTIMIZE
· DATA ANALYSIS – TIME
STUDY
· IDENTIFY OPTIMIZED · VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
· DETERMINE RESOURCE · DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
· DOCUMENT · COMMUNICATE RESULTS
STANDARIZED WORK FOR · BUILD SIMULATION MODEL
FUTURE STATE
15
Plan
IDENTIFY SCOPE
MODULES MEASURE
Identify Scope Modules
· DEVELOP PROCESS FLOW · MEASURE WORK- TIME
CHART AND MOTION STUDY
· UNDERSTAND THE PROCESS APPLICATION
· DEFINE VARIABLES · COLLECT/RECORD
· ASSESS NEEDED DATA
• Develop Process Flow Chart
·
RESOURCES
SELECT MEASUREMENT
·
·
MONITOR OUTPUTS
CATEGORIZE THE
•
SYSTEM
·Understand the process
RESULTS
PLAN DATA COLLECTION
MODULES n
• Define Variables Pla
D
O
• Determine Work Measurement
approach
• Assess needed resources
• Create matrix and plan data
collection phase and modules
dy
A
C
t u
T
S
ASSESS AND
COMMUNICATE
OPTIMIZE
· DATA ANALYSIS – TIME
STUDY
· IDENTIFY OPTIMIZED · VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
· DETERMINE RESOURCE · DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
· DOCUMENT · COMMUNICATE RESULTS
STANDARIZED WORK FOR · BUILD SIMULATION MODEL
FUTURE STATE
16
DO
IDENTIFY SCOPE
MODULES MEASURE
D
O
• Collect and record data
• Monitor outputs
• Categorize the results
y
A
ud
C
t
T
S
ASSESS AND
COMMUNICATE
OPTIMIZE
· DATA ANALYSIS – TIME
STUDY
· IDENTIFY OPTIMIZED · VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
· DETERMINE RESOURCE · DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
· DOCUMENT · COMMUNICATE RESULTS
STANDARIZED WORK FOR · BUILD SIMULATION MODEL
FUTURE STATE
17
Study Example
IDENTIFY SCOPE
MODULES MEASURE
D
O
Assess and communicate
t u
T
• SCommunicate results
• Build simulation model
ASSESS AND(static
OPTIMIZE or dynamic) COMMUNICATE
· DATA ANALYSIS – TIME
STUDY
· IDENTIFY OPTIMIZED · VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
· DETERMINE RESOURCE · DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
· DOCUMENT · COMMUNICATE RESULTS
STANDARIZED WORK FOR · BUILD SIMULATION MODEL
FUTURE STATE
18
Act
IDENTIFY SCOPE
MODULES MEASURE
D
O
Optimize
ud
C
t
T
S
scheduling, etc.
• Document future state ASSESS AND
COMMUNICATE
standardized
OPTIMIZE work. · DATA ANALYSIS – TIME
STUDY
· IDENTIFY OPTIMIZED · VALIDATE CURRENT
STATE OF PARAMETERS APPROACH
· DETERMINE RESOURCE · DETERMINE RESOURCE
ALLOCATION AVAILIBILIY
· DOCUMENT · COMMUNICATE RESULTS
STANDARIZED WORK FOR · BUILD SIMULATION MODEL
FUTURE STATE
19
Why Work Measurement?
To:
Assess Capabilities
Establish Expectations
20
Work Measurement Methods
SWAG
Estimation
Historical Data
MODAPTS
Predetermined
Time Systems MOST
MTM
21
Which Method?
VOLUME CYCLE TIME RECOMMENDED TECHNIQUE
LONG Work Sampling
1000'S MEDIUM Work Sampling, Time & Motion Study
SHORT PTSS
22
• “My employer has a implemented a lean initiative
over 4 years ago, yet has only a very rudimentary time
study. Actually, it is only a conversion from (inaccurate)
pay rates to time.
• The result is waste has not been reduced from our
manufacturing operations.”– IIE Blog
24
Estimation
Historical
SWAG
Data
25
Estimation
Available Subjective
Quick Not a good source for time
No need for formalized standards
work measurement Inflated time due to delay and
program non-optimal performance
Less costly Difficult to set higher goals
Difficult to update standards
26
Observation
27
Time & Motion Study History
28
Phases of a time study
Analysis
Measurement
Synthesis
Operator
Working Conditions
Methods
Break Down the tasks to elements
30
Operator
Who do we study?
Normal Representative
& Qualified
31
Normal Operator
Inadequate Climate
Mental workload
Visual fatigue
34
What is the Rule of Thumb?
36
37
Example
38
Jobs, Innovation, Growth, Stability www.ies.ncsu.edu
Measurement
Phase
40
How do we determine sample size?
Statistical method
Conventional method
41
Statistical Method of Sample Size
• Accuracy desired
• Confidence desired
• Data variability
Formula
Provide an
example
42
Conventional Method for Sample Size
43
There are all kinds of factors that have to be
considered!!!!!!!
• Westinghouse system
• Synthetic rating
• Pace rating
• Objective rating
45
How Do We Performance Rate the
Operator?
47
Allowances
Personal
Fatigue
Delays
• Avoidable
• Non-Avoidable
48
49
Direct observation
• Actual Observation of current
practices- GEMBA
• Open dialog with people that
perform the job
PROS • Quick results
• Actual utilization of the
operators
• Work Load Evaluation
• Requires continuous
maintenance
CONS
• Does not lend itself to variety of
product mix
50
Direct Time Study Devices
51
Time Study Steps
Observe and record information
Machine Set up
Operator Method Lay out Equipment Used Working Condition
(speeds & feeds)
Communicate
With operator With Supervisor All People involved in the process
Determine allowance
53
Work Sampling Steps
Identify the
Summarize,
Define Define the observers Collect Data
Design the analyze and
Operation task who will do (as per
study report the
Tasks elements the design)
results
Sampling
54
Observation
56
PMTS Procedures
MODAPTS
MOST
MTM
57
MODAPTS
58
MOST (Maynard Operation Sequence
Technique )
Parameters: Categories:
• A= Action • Reach
Distance • Gain
• B= Body Motion • Move
• G= Gain Control • Place
• P= Placement • Return
59
MOST Procedure
Observe job/task
Determine
sequence(s) to use
Determine index
values
Multiply TMU by 10
MTM Categories
Reach
Move
Turn
Apply Pressure
Grasp
Position
Release
Disengage
Body Motions
Eye Motions
61
Industrial Extension Service
MTM Tables
62
PRE-DETERMINED TIME
64
Time Study - Rules
Involve
Employees
Have
Prepare and
information
Motivate
and manage
People
expectations
Success in
work
Measurement
Program
Benefits of Work Measurement