UNIT 01

Work Study Method

Work study is the investigation, by means of a consistent system of the work done in an
organization in order to attain the best utilisation of resources i.e. Materials, Machines, Men and
Money. All the technologies and management systems are related with productivity.

Or

The work-study method is a systematic approach to improving efficiency and productivity in the
workplace. It involves analyzing work processes and tasks to identify and eliminate
inefficiencies, reduce waste, and optimize performance. The work-study method consists of two
main components: method study and work measurement.

Method Study

Method study focuses on improving the way tasks are performed. The steps involved include:

1. Selecting the Work: Identifying the process or task that needs improvement.
2. Recording the Existing Method: Documenting the current method using various
techniques such as flow charts, diagrams, and written descriptions.
3. Examining the Existing Method: Analyzing the recorded method to identify areas of
inefficiency and potential improvement.
4. Developing a New Method: Creating an improved method that eliminates inefficiencies
and optimizes performance.
5. Installing the New Method: Implementing the new method in the workplace.
6. Maintaining the New Method: Ensuring the new method is followed and making
adjustments as necessary.

Work Measurement

Work measurement is concerned with determining the time required to perform a task. The steps
involved include:

1. Selecting the Work to be Measured: Choosing the specific task or process for
measurement.
2. Recording the Time Taken: Using techniques such as time study (stopwatch timing) or
predetermined motion time systems (PMTS) to record the time taken to complete the
task.
3. Analyzing the Data: Evaluating the recorded times to determine the standard time for
the task, considering factors such as rest periods and delays.
4. Establishing a Standard Time: Setting a standard time for the task that can be used for
planning, scheduling, and labor costing.
5. Implementing and Maintaining the Standard Time: Applying the standard time in the
workplace and ensuring it is adhered to, making adjustments as necessary.
Role of Work Study:

 To eliminate unnecessary human movements.

 To standardise the method of doing a work.
 To determine the standard time for doing a task.
 To a systematic investigation of all factors.
 To minimise the unit cost of production.
 To minimise the material movement, and operator’s movement.
 To utilise facilities such as man, machine and materials most effectively.

Benefits of Work Study

 Increased Efficiency: By identifying and eliminating inefficiencies, the work-study

method helps to streamline processes and increase productivity.
 Reduced Costs: Improved methods and optimized performance lead to cost savings.
 Improved Quality: Standardized methods and performance measures contribute to
higher quality output.
 Enhanced Worker Satisfaction: Clear methods and fair performance standards can lead
to improved job satisfaction and morale.

Techniques Used in Work Study

 Flow Process Charts: Visual representations of the steps involved in a process.

 Time and Motion Studies: Detailed observation and timing of tasks to identify areas for
improvement.
 Work Sampling: Statistical technique to estimate the proportion of time spent on
different activities.
 Critical Path Analysis (CPA): Technique used to identify the sequence of crucial steps
and their timings in a project.

Production Technology

In the simplest sense, production technology is the machinery that makes creating a tangible
physical product possible for a business. To the small business, this means a workshop at the
very least, with more elaborate operations making use of machines and assembly lines. Choosing
a production scale model within a company’s capital means is important; simpler workshops
tend to lead to lower production volume but cost less to assemble, while higher output operations
require more complex and costly machines, which are sometimes cost prohibitive.
 Component of production technology

1.The Modern Artisan Workshop

he concept of a Modern Artisan Workshop integrates traditional craftsmanship with modern

technology and sustainable practices to create high-quality, customized products. This hybrid
approach leverages the best of both worlds: the meticulous attention to detail and personalized
touch of artisanship, alongside the efficiency, precision, and scalability provided by modern
manufacturing technologies. Here are key components and characteristics of a Modern Artisan
Workshop:

Key Components and Characteristics

 Combination of Traditional and Modern Techniques

o Traditional Craftsmanship: Skilled artisans use hand tools and traditional
methods to create unique, high-quality items. Techniques such as hand-stitching,
carving, and weaving are often employed.
o Modern Technology: Integration of digital tools such as CNC machines, laser
cutters, 3D printers, and computer-aided design (CAD) software to enhance
precision and efficiency.

 Customization and Personalization

o Bespoke Products: Customers can customize products according to their
preferences, ensuring a unique and personalized experience. This may include
custom sizing, materials, colors, and design elements.
o On-Demand Production: Products are often made to order, reducing waste and
overproduction.

 Sustainable Practices
o Eco-Friendly Materials: Use of sustainable, ethically sourced materials to
minimize environmental impact.
o Waste Reduction: Efficient use of materials and recycling of scraps to reduce
waste.
o Energy Efficiency: Implementation of energy-efficient processes and equipment
to lower the carbon footprint.

 High Quality and Attention to Detail

o Meticulous Craftsmanship: Emphasis on quality over quantity, with careful
attention to detail in every step of the production process.
o Quality Control: Rigorous quality checks to ensure that each product meets high
standards before it reaches the customer.

 Collaboration and Innovation

o Interdisciplinary Teams: Collaboration between artisans, designers, and
engineers to create innovative products that blend aesthetics and functionality.
 o Continuous Improvement: Ongoing learning and adaptation of new techniques
and technologies to improve processes and products

2.CNC Machining and Extending the Artisan Workshop

A computer number-controlled or CNC machine – also referred to as computer-aided

manufacturing – further extends the capability of an artisan workshop, allowing the skilled
craftsman to program the device to perform highly detailed repetitive tasks such as router and
drill operation. CNC machines are expensive investments; however, when used to address the
more time-consuming steps of producing an item in the standard artisan workshop, they can
significantly improve the overall profitability of that manufacturing business. Because of their
high initial cost when compared to manually operated shop tools, CNC machines are generally
unavailable to all but the most successful small business. Investing in a CNC machine is a
pivotal decision for a small business and should be done with careful consideration of how much
the machine will actually boost profits when compared to continuing with the manual method.

Explanation :-

A computer number-controlled (CNC) machine, also known as computer-aided manufacturing,

helps an artisan workshop by allowing skilled craftsmen to program it to do detailed and
repetitive tasks like routing and drilling. CNC machines are expensive, but they can make a
workshop more profitable by speeding up the production of items. Because of their high cost,
only the most successful small businesses usually have them. Investing in a CNC machine is a
big decision for a small business and should be carefully considered to see if it will really
increase profits compared to doing the work manually.

3. Automated Assembly Line-Style Mass Production

Automated assembly-line mass production is the peak of modern industrial production, used by
big companies like car makers and appliance manufacturers. The more machines and robots are
used, the fewer human workers are needed, but the initial cost of these robots is very high.
Because of this high cost, small businesses usually can't afford automated assembly lines. Also,
maintaining these advanced systems requires skilled robotics technicians, making it even harder
for small businesses to use this method.

4. Practicality Considerations for Small Business

When investing in production technology, small businesses should aim to get the best return on
investment within their budget. According to the IRS, small businesses are successful if they
make a profit in at least three out of every five years. This means if it takes more than two years
to pay off the investment in production technology, the business likely spent too much. However,
small and medium businesses don't have to avoid advanced production methods entirely. They
can adapt practices from larger industries to fit their needs. For example, they can use a simple
conveyor belt and divide the work among employees to speed up production while still using
traditional tools.

Plant Location

Plant Location refers to the strategic decision-making process of selecting an optimal site for
establishing a manufacturing facility or production plant. This decision is influenced by various
factors such as proximity to raw materials and suppliers, transportation infrastructure, access to
markets, labor availability, cost considerations, regulatory requirements, and environmental
factors. The goal of plant location planning is to minimize production costs, optimize logistics
and supply chain efficiency, reduce operational risks, and enhance overall competitiveness.

Features of Plant Location

 Proximity to Raw Materials:

Locating near sources of raw materials reduces transportation costs and ensures a steady supply
chain, minimizing inventory holding costs and production delays.
 Access to Transportation Networks:
Easy access to highways, railways, ports, and airports facilitates efficient distribution of products
to markets and reduces logistics costs.
 Availability of Skilled Labor:
Plant locations with access to a skilled workforce reduce training costs and improve operational
efficiency, as skilled labor is crucial for maintaining production quality and meeting demand.
 Market Accessibility:
Locating close to target markets reduces distribution costs and lead times, enhancing
responsiveness to customer demands and market fluctuations.
 Cost of Land and Utilities:
Affordable land prices and access to reliable utilities such as water, electricity, and
telecommunications lower operational costs and improve cost competitiveness.
 Infrastructure and Government Support:
Supportive infrastructure (e.g., industrial parks, technology clusters) and favourable government
policies (e.g., tax incentives, regulatory environment) can attract investment and promote
business growth
Scope of Plant Location:

Optimal Resource Utilization

Supply Chain Management

Market Penetration

Operational Efficiency

Risk Management

Environmental Considerations

Strategic Expansion

Types of plant location

Four Main Types of Plant Layout:-

1. Product or Line Layout

2. Process or Functional Layout.
3. Fixed Position Layout.
4. Combination type of Layout.

1. Product or Line Layout

If all the processing equipment and machines are arranged according to the sequence of operations of the
product, the layout is called product type of layout. In this type of layout, only one product of one type of
products is produced in an operating area. This product must be standardized and produced in large
quantities in order to justify the product layout.
The raw material is supplied at one end of the line and goes from one operation to the next quite rapidly
with a minimum work in process, storage and material handling. Fig. 8.3 shows product layout for two
types of products A and B.

Advantages offered by Product Layout:

(i) Lowers total material handling cost.
(ii) There is less work in processes.
(iii) Better utilization of men and machines,
(iv) Less floor area is occupied by material in transit and for temporary storages.
(v) Greater simplicity of production control.
(vi) Total production time is also minimized.

Limitations of Product Layout:

(i) No flexibility which is generally required is obtained in this layout.
(ii) The manufacturing cost increases with a fall in volume of production.
(iii) If one or two lines are running light, there is a considerable machine idleness.
(iv) A single machine break down may shut down the whole production line

2. Process or Functional Layout

The process layout is particularly useful where low volume of production is needed. If the
products are not standardized, the process layout is more low desirable, because it has creator
process flexibility than other. In this type of layout, the machines and not arranged according to
the sequence of operations but are arranged according to the nature or type of the operations.
This layout is commonly suitable for non repetitive jobs.

Same type of operation facilities are grouped together such as lathes will be placed at one place,
all the drill machines are at another place and so on. See Fig. 8.4 for process layout. Therefore,
the process carried out in that area is according to the machine available in that area.

Advantages of Process Layout

(i) There will be less duplication of machines. Thus, total investment in equipment purchase will
be reduced.
(ii) It offers better and more efficient supervision through specialization at various levels.
(iii) There is a greater flexibility in equipment and man power thus load distribution is easily
controlled.
(iv) Better utilization of equipment available is possible.

Types of Plant layout

Four Main Types of Plant Layout

1. Product or Line Layout

2. Process or Functional Layout.
3. Fixed Position Layout.
4. Combination type of Layout.
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1. Product or Line Layout

If all the processing equipment and machines are arranged according to the sequence of
operations of the product, the layout is called product type of layout. In this type of layout, only
one product of one type of products is produced in an operating area. This product must be
standardized and produced in large quantities in order to justify the product layout.

The raw material is supplied at one end of the line and goes from one operation to the next quite
rapidly with a minimum work in process, storage and material handling. Fig. 8.3 shows product
layout for two types of products A and B.

Advantages offered by Product Layout:

(i) Lowers total material handling cost.

(ii) There is less work in processes.
(iii) Better utilization of men and machines,
(iv) Less floor area is occupied by material in transit and for temporary storages.
(v) Greater simplicity of production control.
(vi) Total production time is also minimized.
Limitations of Product Layout:
(i) No flexibility which is generally required is obtained in this layout.
(ii) The manufacturing cost increases with a fall in volume of production.
(iii) If one or two lines are running light, there is a considerable machine idleness.
(iv) A single machine break down may shut down the whole production line.
(v) Specialized and strict supervision is essential.

2. Process or Functional Layout

The process layout is particularly useful where low volume of production is needed. If the
products are not standardized, the process layout is more low desirable, because it has creator
process flexibility than other. In this type of layout, the machines and not arranged according to
the sequence of operations but are arranged according to the nature or type of the operations.
This layout is commonly suitable for non repetitive jobs.

Same type of operation facilities are grouped together such as lathes will be placed at one place,
all the drill machines are at another place and so on. See Fig. 8.4 for process layout. Therefore,
the process carried out in that area is according to the machine available in that area.
Advantages of Process Layout

(i) There will be less duplication of machines. Thus, total investment in equipment purchase will be
reduced.
(ii) It offers better and more efficient supervision through specialization at various levels.
(iii) There is a greater flexibility in equipment and man power thus load distribution is easily controlled.
(iv) Better utilization of equipment available is possible.
(v) Break down of equipment can be easily handled by transferring work to another machine/work
station.
(vi) There will be better control of complicated or precision processes, especially where much inspection
is required.
Limitations of Process Layout
(i) There are long material flow lines and hence the expensive handling is required.
(ii) Total production cycle time is more owing to long distances and waiting at various points.
(iii) Since more work is in queue and waiting for further operation hence bottle necks occur.
(iv) Generally, more floor area is required.
(v) Since work does not flow through definite lines, counting and scheduling is more tedious.
(vi) Specialization creates monotony and there will be difficult for the laid workers to find job in
other industries.

3.Fixed Position Layout

This type of layout is the least important for today’s manufacturing industries. In this type of
layout the major component remain in a fixed location, other materials, parts, tools, machinery,
man power and other supporting equipment’s are brought to this location.

The major component or body of the product remain in a fixed position because it is too heavy or
too big and as such it is economical and convenient to bring the necessary tools and equipment’s
to work place along with the man power. This type of layout is used in the manufacture of
boilers, hydraulic and steam turbines and ships etc.

Advantages Offered by Fixed Position Layout

(i) Material movement is reduced

(ii) Capital investment is minimized.
(iii) The task is usually done by gang of operators, hence continuity of operations is ensured
(iv) Production centers are independent of each other. Hence, effective planning and loading can
be made. Thus total production cost will be reduced.
(v) It offers greater flexibility and allows change in product design, product mix and production
volume.
Limitations of Fixed Position Layout
(i) Highly skilled man power is required.

(ii) Movement of machines equipment’s to production centre may be time consuming.

(iii) Complicated fixtures may be required for positioning of jobs and tools. This may increase
the cost of production.

4.Combination Type of Layout

Now a days in pure state any one form of layouts discussed above is rarely found. Therefore, generally
the layouts used in industries are the compromise of the above mentioned layouts. Every layout has got
certain advantages and limitations. Therefore, industries would to like use any type of layout as such.

Flexibility is a very important factory, so layout should be such which can be molded according to the
requirements of industry, without much investment. If the good features of all types of layouts are
connected, a compromise solution can be obtained which will be more economical and flexible .

IMPORTANT QUE$STION CONSIDERING EXTERNAL EXAMS

1. Different b/w operation management and production management.
2. Role of plant Layout in sustainable production?
3. Differentiate between plant layout and location layout?
4. Factor influencing the selection of plant layout?
5. What is work study and work measurement?
6. What are the role of time and motion study plays in work study methodology?
7. Role of operation management in present scenario
8. Component of production technology