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(R.S) Imroving Productivity Through Work Study PDF
(R.S) Imroving Productivity Through Work Study PDF
(R.S) Imroving Productivity Through Work Study PDF
Abstract
The objective of this paper is to present an overview on a new combined methodology for the efficient improvement in productivity
with the help of various Work Study Methods associated with Lean Manufacturing Principles & Tools. Lean manufacturing tools are
one of the most influential & most effective methodologies for eliminating wastes (MUDA), controlling quality, and improving overall
performance of any machine, system or process in any industry with the complete assurance of large annual profit margins. This
prescriptive paper proposes genuine solutions & concepts for implementing Work Study Methods and deploying associated lean
manufacturing tools in any enterprise or industry, covering the technical, engineering, and manufacturing aspects as well as the
business etiquette affairs. Lean Manufacturing together with Work Study Methods, being the most sophisticated & vast area of studies
has a huge scope for implementation & deployment of their very own concepts.
Keywords: 5S, Wastes (Muda), Time & Method Study, Setup Time Reduction (SUR), Standardized Work (SDW).
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Considering the inclination towards a customer-focused 1.2 Role of Work Study in Improving Productivity
environment while facing fierce juxtapositions, majority of
manufacturers are implementing Work Study Methods along Work Study is the systematic methodology of carrying out
with lean manufacturing tools to help eliminate wastes and different yet related activities such as to improve the efficient
increase proficiencies rather than depending on conventional use of resources and to set up standards of performance &
processes and procedures [8]. According to many researchers, quality for the activities to be carried out.
using Lean Tools is the best way to improve productivity by
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Volume: 03 Issue: 02 | Feb-2014, Available @ http://www.ijret.org 429
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319
2319-1163 | pISSN: 2321-7308
In simple language, it may be defined as the analysis of a job Bottleneck Analysis is usually done along with the Time
for the sheer purpose of finding the subsequent method of Study Method. The system on which the analysis is required to
doing it and also determining the required standard time to be done is first selected. Then in the form of ‘Daily Analysis’,
perform it by the selected or given method. [9] ‘Minute to Minute Analysis; or ‘Macro Second Study
Analysis’ the entire process is carried out along with the
Work Study generally is classified in two areas: Method study guidance of Time Study Methods.
(Motion study) and Time study (Work measurement).
An example of Minute to Minute Bottleneck Analysis is as
2. LEAN TOOLS shown in the figure below
Lean tools have not been derived or proposed in one single Time (Min) Down Time (Min) Remark
day. They have been derived from the rresearch of many 7.00 To 7.34 34.00 Operator Absent
7.34 To 7.44 10.00 Machine Setting and Parameters Checking
people throughout the history. As they are why very complex 7.44 To 7.51 7.00 Single job produced, Lab testing for quality
& interdependent on each other and one can find similarities 7.51 To 8.10 19.00 Power Loss
8.10 To 8.19 9.00 Operator Absent, M/c stopped due to power loss
in one another. 8.19 To 8.27 27 no's produced
8.27 To 8.32 5.00 Machine Stopped, Point problem
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Volume: 03 Issue: 02 | Feb-2014, Available @ http://www.ijret.org 431
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319
2319-1163 | pISSN: 2321-7308
3. WORK STUDY METHODS Ass seen earlier, Method study focuses to achieve the better
method of doing work, and for this reason method study is
In order to understand the work study methods, we need to sometimes called Work Method Design.
understand the importance of method study and that of time The following steps depict
pict the procedure for creating a method
study. ‘Method study’ (sometimes also called Work Method study.
Design) is mostly used to improve the method of doing work.
wor 1. Select (the work to be studied).
Whenen applied to existing products, method study aims to 2. Record (all relevant information about that work).
allocate better methods of manufacturing the jobs that are safe, 3. Examine (the recorded information).
effective, & economical, require mitigated human effort, and 4. Develop (an improved way of doing things).
need smaller make-ready
ready time. The better method involves the 5. Install (the new method as standard practice)
optimum use of best materials and appropriate manpower so 6. Maintain (the new standard proactive).
that work is performed in well-organized
organized manner leading to
increased
sed resource utilization, optimized quality and appeased
3.2 Time Study (Work Measurement)
costs.
Work measurement refers to the estimation
esti of standard time
for an activity that is the time specific for completing one job
WORK
STUDY by using the predicted method. Standard time can be defined
as the time utilized by an average experienced skillful operator
for the job with provisions for delays beyond the operator’s
control.
A work has to be measured for the following reasons:
METHOD STUDY TIME STUDY
Scrutinizing a Product & Deciding the time required to • To identify and eliminate missing or ineffective time.
searching more proficient perform a job & its associative • To install standard times for performance & quality
methods to carry it. precautions.
measurement.
• To measure performance against original expectations.
Fig -4: Work Study Methods • To set manufacturing & operating objectives.
It can therefore be stated that through 'Method study' one can Time study can be simply defined as a technique to estimate
have a systematic way of developing human resource the time to be allowed to a qualified and well-trained
well worker
ascendancy, providing elevated machine
achine and equipment use
use, working at a normal pace to complete a specified task by using
and making economical use of raw materials. ‘Time study’, specified method.
however, provides the standard required time, that is the time
needed by worker to complete a job by the standard method.
By the application of method study and time study together
with Lean Tools, any industryy can thus achieve greater output
at less cost and of better quality, and hence can easily achieve
higher productivity. [9]
Select
Maintain Record
Install Examine
Develop
4. SETUP TIME REDUCTION (SUR) Setup Reduction allows batch size reduction, which is critical
for continuous flow manufacturing & improves manufacturing
Setup is a set of activities to be prepared for the next part or flexibility.
process, Whereas, Setup Time is the total elapsed time from
completion of the last good part from the previous setup to the The following five-step approach to setup reduction may be
completion of the first good part from the new setup. Setup used to achieve efficient results –
Time Reduction or Change-over Time Reduction is defined as
the efficient reduction time to change from the last item of the
previous order to the first good item of the next order in order
to obtain increased productivity. [11]
• Setup time reduction improves the equipment Once the industry gets hold of the detailed problems, they can
availability, increasing the total capacity & results in: be categorized in substantial groups in order to maintain their
– Better utilization of operator’s time. integrity & so that, efficient solution on a particular problem
– Better utilization of resources & capital cost. can easily be obtained. With Critical Lean tools stated above,
– Reduced capital investment. problems can be efficiently classified in corresponding area
and those tools can be applied one by one to get long lasting
• Reduced setup time makes smaller batch sizes results along with improved productivity as well as profit
possible, without the economic penalty, resulting in reduced: margin.
– Overall lead times.
– Inventory & storage space needs.
– Reject rates.
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Volume: 03 Issue: 02 | Feb-2014, Available @ http://www.ijret.org 433
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319
2319-1163 | pISSN: 2321-7308
BIOGRAPHIES
Prathamesh Pramod Kulkarni,
Kulkarni Pursuing Final
Year in Bachelor of Mechanical Engineering
degree from GES’s R.H.S. C.O.E, Nashik,
under the affiliation of University of Pune,
Maharashtra, India.
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Volume: 03 Issue: 02 | Feb-2014,
2014, Available @ http://www.ijret.org 434