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Work Measurement
Work Measurement
CO 3: Students will be able to rate a worker engaged on a live job and calculate
basic, allowed and standard time for the same.
CO 4: Students will be able to provide appropriate allowances for the jobs under
analysis.
CO 5: Students will be able to calculate the rate of wage andincentive for the
employees of an organization.
CO 6: Students will be able to analyze and calculate the level of risk of the job
causing stress, fatigue and musculoskeletal disorders among the employees of
an organization.
CO 7: Students will be able to assess the occupational environmental factors like
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING heat stress, noise, and vibration and RSPM level in the industry.
WORK STUDY (WORK MEASUREMENT) 1 WORK STUDY (WORK MEASUREMENT) 2
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TIME STUDY
Basic Steps
a) Obtaining and recording all available information about the job, operator
Steps in Work Measurement
and the surrounding conditions likely to affect the execution of the work
1. Selection:- As it follows the method study, the selection
b) Recording the complete description of the method, breaking down the process is already done. But it should eliminate the inferior
operation into 'elements' methods, as it won’t justify the cost & efforts involved.
c) Measuring with a stopwatch and recording the time taken by the 2. Obtain the necessary information. In terms of worker,
operator to perform each 'element' of the operation. machines, material, quality, standards, layout etc.
d) Assessing the rating
e) Extending observed time to 'basic times'
f) Determining the allowances to be made over and above the basic time
for the operation
g) Determining the 'standard time' for the operation.
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Steps in Work
Measurement Steps in Work Measurement
3. Divide the job into elements. The division of jobs is 4. Time the elements. Stop watch is generally used in the
necessary for the following reasons. system. Either of continuous or Fly-back method is used for
recording time.
a. Provide better understanding.
b. Break the study into manageable size. 5. The number of cycles to be timed. There should be
sufficient readings to get reasonably accurate results. It
c. Workers efficiency thorough out job. depends on
d. Distinguish between various parts. 1. Variation in times of element.
e. Isolate man and machines. 2. Degree of accuracy required.
3. Prescribed level of confidence.
5. Rating of operator.
6. Objective rating. Here emphasis is laid on speed and
difficulty experienced in performing a job. At first operator is
rated on normal speed and movement. Then other factors
are considered.
7. Allowances.
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Contingency
allowance
Standard Time Observed time
Rating factor
Unavoidable
Relaxation
Allowance
delays
greater than standard pace)
Basic time
Work content
Standard time
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Allowances Allowances
It is very important to understand the fact that the calculation of
allowances cannot be accurate under all the circumstances and also
There is always need of some energy expenditure in the form of human allowance can’t be used as a dumping ground for any of the missed or
effort or the worker may need to spend some time for his personal neglected factors during the time study. In order to arrive at fair and
needs like; going to toilet, drinking water, getting material or tools, or to accurate time standards, as the study man can go to greater extent of
get instructions from the supervisor of the shop floor. thoroughness.
Hence in order to recover from fatigue, some rest allowance must be Hence, these cannot be afforded to ruin by the hurried or unplanned
provided. addition of a few points here and there “just in case”. In practical
conditions it is very difficult to prepare a universally accepted set of
Some allowance must also be provided to a worker to attend to his precise allowances that can be applied to every working situation
personal needs and alongside some contingency allowances may have anywhere in the world, and there are various reasons for the same,
to be added to the basic time in order to give the work content. however some of the most important among them are:
Factors related to the individual worker.
Factors related to the nature of the work
Factors related to the environment
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Types of Elements
Types of Elements
1. Repetitive element: It is the element that occurs in every work cycle of 5. Manual element: It is an element performed by worker e.g. manual
the job e.g. Picking up a part prior to an operation. sweeping of the floor.
2. Occasional element: It is that one which does not occur in each work 6. Machine element: A machine element is one, which is automatically
cycle of the job, but which may occur in regular or irregular intervals performed by a power driven machine for e.g. turning, facing, cutting on
e.g. cleaning the scrap from the machine tools. an automatic machine tools.
3. Constant element: The reading of basic time remains invariable for this 7. Governing element: The element which takes longer time than that of
element whenever it is performed e.g. Switching on or off machine. any other element which is being performed consecutively e.g. turning
diameter on a lathe. While gauging time to time.
4. Variable element: It is the element in which the basic time varies as per
characteristic of the product, tool, process e.g. dimension, weight, 8. A foreign element: The element is observed during a study which is
quality etc. for e.g. Pushing a trolley of components to other section. not found to be a necessary part of the job after analysis e.g. cleaning a
part yet to be machined.
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With first pressing of the winding knob the watch starts and long hand
begins moving. If winding knob is pressed again the long hand pauses and
with third pressing, hands come to initial position. In the case of timing two
parts, where the second part happens right after the first, the non-fly back
system doesn’t work well because it involves stopping the watch at the end
of the first part, pressing the knob to bring hands back to zero, and again
pressing the knob to start the hands.
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In continuous timing
In continuous timing method, a non-fly back type of stopwatch is
Repetitive Timing
utilized. In this method the stopwatch is started at the beginning of first
element and run continuously all through the period of the study. The In the repetitive timing, also known as snap back method, a fly back type
reading of the watch is noted at the end of each element and the same of stopwatch is used. At the beginning of first element the observer snaps
is recorded on the observation sheet opposite its name or serial the hand back to zero by pressing the winding knob of the watch. The
number. The time for each element is determined later by subtraction hand moving forward immediately begins to measure the time for the
as explained in Table first element. At the end of the first element, the observer reads the
watch, snaps the hand back to zero and then records his reading. In the
same manner the observer times the rest of the elements. This method
of timing gives the direct time without subtraction and the data are
recorded on the observation sheet as read from the watch. This system
has one disadvantage that the observer has to read the stopwatch while
its hands are moving
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The constituents of standard time are Example: Consider fatigue allowances as 10%, process allowances 5%,
contingency allowances 5%, and policy allowance is 20%. Let us
diagrammatically represented as calculate the normal rime, sustained time, allowed time and standard
time for the operation. The time recorded for the four elements is
follows. shown in Table below
Observed Rating Factor Rest Process Special Policy
Time Allowance Allowance Allowance Allowance Element No. 1 2 3 4
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Solution
Element No. 1 2 3 4
Solution:
Cycle No. Stopwatch reading in seconds
1 10 20 20 20
2 20 17 18 20
3 10 20 20 20
4 15 15 20 15
5 10 20 20 20
Average
Average Rating 110 110 120 90
Normal Time
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Q. Compute the production cost per piece from the following data:
direct material per piece = Rs 2, wage rate Rs 2000 per month consisting
of 25 working days and 8 hours per day
Solution
over head expressed as a % of direct level cost =200%
Element Average observed time
The time for manufacture of 4 pieces of the item was observed during
time study. (O.T) in minutes
The manufacture of the item consist of 4 elements a, b, c, d. the data
collected during the time study are as under.
A
The personal, fatigue and delay allowances may be taken as ± 25%. Time
observed (mins) during the various cycle are as below:
B
1. Are they any outliers in the data i.e. probable errors in reading or
recording data which should not be included in the analysis?
2. Compute the basic time for the job and the standard time. If a
relaxation data allowances of 12 %, a contingency allowance of 3 % and
an incentive of 20% are applicable for the job
WORK STUDY (WORK MEASUREMENT) 51 WORK STUDY (WORK MEASUREMENT) 52
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Advantages:
1. Inexpensive to apply and usually cost is significantly less than continuous Establishing confidence levels
time study.
Let us go back to our previous example and toss five coins at a time, and
2. Used to determine various impractical actions which are difficult to measure then record the number of times we have heads and the number of
by time study. times we have tails for each toss of these five coins. Let us then repeat
this operation 100 times.
3. Trained work measurement analyst are not essential to make observation.
4. Work sampling measurement can be made with a predetermined assigned
level of consistency.
5. Directly measure the working/engagement of individuals and equipment.
6. Eliminate the need of stopwatch for measurement.
Limitations:
1. Does not recommend several of the opportunity for methods study that
accompanies time; study and less improved work methods.
2. The worker may be unable to understand statistical work sampling.
3. The results may be unfair if random sampling is not done.
95 per cent confidence level or 95 per cent of the area under the curve Determination of sample size
= l.96 σp;
• 99 per cent confidence level or 99 per cent of the area under the
curve = 2.58 σp;
• 99.9 per cent confidence level or 99.9 per cent of the area under the
curve = 3.3σp;
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In the present case let us assume that we shall carry out our
observations during a day shift of eight hours, from 8 am to 4 pm. An
eight-hour day has 480 minutes. These may be divided into 48 ten-
minute periods.
We can start by choosing any number at random from the random
number Table.
For example let us close our eyes and place a pencil point somewhere
on the table. Now, let us assume that in this case we pick number 20, by
mere chance, which is in the first block, fourth column, and fourth row
as shown in Table
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Work sampling record sheet showing observation on Work sampling record sheet showing observation on
distribution of machine idle time of nine elements of distribution of machine idle time of nine elements of
operation performed operation performed
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