Work Measurement

PFC & Time Study

IE Webinar
Work Measurement PFC & Time Study
Webinar
W-IE-113

• Rev-1.1

W-IE-113
 MODULE CONTENT

 Engineered Work Standard

 Work Study

 Method: Process Flow Chart

 Measurement: Time Study

 Rating

 Personal Fatigue & Delay PF&D%

 Standard Time

 Data Storage

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 WORK STANDARD - IMPORTANCE

An optimized method and a correct

standard time of the operation will
allow us to:

Baseline for future improvements

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 WORK STUDY – METHOD STUDY

To define an engineered work standard a Work Study

needs to be performed.
Work
Study
This contains 2 main tasks:

- Method Study, and

- Work Measurement

A Method Study is concerned with the reduction of the

Work
Method Study
Measurement work content of an operation to define the ‘best method’
using techniques like:

- Process Flow Chart (PFC) - NVA / VA analysis

- Ergonomic assessment - Flow (spaghetti) diagram
- Man-Machine Analysis - Etc.

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 WORK STUDY – METHOD STUDY

Work
Study The ‘Best Method’ is not always the fastest method!

The Best Method refers to how a job should be done.

Work
Method Study
Measurement
- Fastest, Safest and Easiest
- Deliver the Best Quality
- Most Efficiently

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 WORK STUDY – METHOD - PROCESS FLOW CHART

WHAT IS A PROCESS FLOW CHART (PFC)?

 Visual representation of the steps required to

manufacture a product

 Map the current state of the process and creates

a ‘big picture’ view
Start or Stop
 Process steps represented by
different symbols Operation or Action step

Decision Point, Question

 Symbols linked together with arrows
to show process flow sequence Direction Flow

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 WORK STUDY – METHOD - PROCESS FLOW CHART

WHY USE PROCESS FLOW CHARTS?

 Way to visually represent and share the complete process

 To identify actual and/or future flow or sequence of steps

 To reveal areas for improvement (e.g. unnecessary steps, WIP…)

 To highlight where cycle time data needs to be collected

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 WORK STUDY – METHOD - PROCESS FLOW CHART

PFC GUIDELINES Not ideal

Even flowchart symbol sizes Even spacing between symbols Consistent flow direction

Make all your flowchart symbols the Maintain even spacing both horizontally A flowchart should have a consistent
flow direction.
same height and width, when possible 。 and vertically between symbols 。 Top-to-bottom preferred over
left-to-right. Do not mix.

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 WORK STUDY – METHOD - PROCESS FLOW CHART

PFC Not ideal

GUIDELINES
Consistent flow branch direction Easy to read

Easier to follow the logic if arrow Don’t use too many colors.
directions are consistent. Keep flowchart easy to read.
E.g. ‘YES’ to below, ‘NO’ to right.

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 WORK STUDY – METHOD - PROCESS FLOW CHART

PROCESS FLOW CHARTS – ONGOING PROJECT TO BE STANDARDIZED

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 WORK STUDY - WORK MEASUREMENT

The time for this best method is calculated using one of the
Work following Work Measurement techniques:
Study
- Work Sampling
- Time Study
- MOST
Work
Method Study
Measurement The outcome of a Work Measurement is the Normal Time.

II

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 STANDARD TIME

Normal time = Manual time + Process Time

(Hand) (Machine)

An Allowance, or PF&D%, to take care of

- personal needs (P),
- fatigue or rest time (F), and
- minor delays (D)

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 STANDARD TIME

This Allowance is necessary to get the Standard Time

which a normal operator can achieve on regular basis
under normal operational conditions.​

Standard time = Normal Time + PF&D%

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 WORK MEASUREMENT

Work Measurement techniques

- Work Sampling
- Time Study
- MOST (or another PMTS)

Which WM to Y Already in Y Y
Repetitive work Already best Time Study
Use? content? Production? Method ?

N N N

Work
MOST
Sampling

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 TIME STUDY – DEFINITION

Work Measurement techniques

- Time Study

Time study is a Work Measurement Technique for

determining the Standard Time or Rate of work of a
particular activity/operation (or elements of operation)
through direct observation using a time measuring
device

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 TIME STUDY – DEFINITION

Work Measurement techniques

- Time Study

ADVANTAGES DISADVANTAGES

Fast to apply Subjective (performance rating)

Unable to use before actual

Easy to use
production

Improvement ideas can be found Unable to simulate method

during observation changes

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 TIME STUDY – WHY?

1992: 30 sec.
How is today’s speed so
much faster ?

NASCAR

2019: 12 sec.
Time Study
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 EQUIPMENT USED IN TIME STUDY

1. Stop Watch / Video Camera

2. Time Study Board

3. Time Study sheet

4. Others
(Measuring scale / tape, pencil with eraser, etc.)

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 STEPS IN CONDUCTING TIME STUDY

1 Standardization

2 Operator Selection

3 Record Information
NORMAL TIME
4 Breakdown to Elements

5 Time Measurement 6 Rating

7 Determine PF&D %

8 Calculate Standard Time

9 Enter into IEDB

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 STEPS IN CONDUCTING TIME STUDY

1 STANDARDIZATIO
N
Work Method (work instructions) Material Arrangement Layout

2 OPERATOR
SELECTION
Qualified operator with required knowledge and skill set,
average paced, & right temperament

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 STEPS IN CONDUCTING TIME STUDY

3 RECORD INITIAL
INFORMATION
Fill Time Study sheet Header:

Sketch layout and other information

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 STEPS IN CONDUCTING TIME STUDY

4 BREAK DOWN
ELEMENTS
 Easily measurable elements with clear start and end points;

 Separate manual, Interactive Machine Times (IMT)

& machine elements

Process

 Split Value-Add (assembly) and Non-Value-Add (Test)

Test Test

Step 1 2 3 4
Value Add Non Value Add Non Value
 Separate Non-cyclic elements Value Add Add

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 STEPS IN CONDUCTING TIME STUDY

5 MEASURE TIME
 Suitable positioning of IE while observing operation and collecting time

 Methods of Timing:

 Cumulative (Continuous) Timing

15 – 10 = 5

 Snapback Timing

 Number of Cycles to study (Sample Size)

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 STEPS IN CONDUCTING TIME STUDY

5 MEASURE TIME – Sampling Size Table-001

Example-1: 5 Initial Readings are 21, 20, 22, 23, 22

Range R = 23 – 20 = 3
Mean X = (21+20+22+23+22)/5 =21.6

R = 3/21.6 = 0.14
X

Required Sample Size = 7

Example-2: Readings are 30, 29, 30, 31, 38, 31, 32, 30, 30, 29
Outlier

For 95% confidence level & accuracy of +/- 5%

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 STEPS IN CONDUCTING TIME STUDY

5 MEASURE TIME (OT)

Breakdown into Types:

 Manual Time (Hand)
 Machine Time (Mach)
 Interactive Machine Time (IMT) Outlier

Note: IMT is ALWAYS ≤ Mach

NC

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 STANDARD TIME - DEFINITION

Normal Time (NT) = Average Observed Time (OT) x Rating Factor (RF)

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 STEPS IN CONDUCTING TIME STUDY

6 RATING

Rating is the assessment of the operator’s rate of working compared

to the Standard Performance
80% < 90% < 100% < 110% < 120%

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 STEPS IN CONDUCTING TIME STUDY

6 RATING
Low Speed Operator – 95%, 90%, 85%, 80%

High Speed Operator – 105%, 110% , 115%, 120%

 Steps of 5%

 80% < RF < 120%

Average [Observed Time (OT) x Rating Factor (RF)] = Average Normal Time (NT)
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 STEPS IN CONDUCTING TIME STUDY

7 CALCULATE ALLOWANCES
PF&D%

Non-Working Time which are considered under Allowances:

 Attending to Personal need

 Rest pauses to overcome Fatigue
 Waiting during short unavoidable Delays or interruptions

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 STEPS IN CONDUCTING TIME STUDY

7 CALCULATE ALLOWANCES
PF&D%
Applicable
Process Description
PF&D%
Manual insertion, light manual assembly, Packing or similar process
done in seated position.
7%

Visual inspection, FNI, OBA requiring eye/mental concentration 8%

Press-fit, ICT, FVT and similar processes involving light material
handling
8%

Manual soldering, Touch-up 8%

Packing, Manual Assembly process involving medium force
application or lifting medium weight
9%

Note: For machine times: no Fatigue factor

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 STEPS IN CONDUCTING TIME STUDY

8 CALCULATE STANDARD TIME

Standard Time = Normal Time + PF&D Allowance

= Normal Time x (1 + PF&D %)

9 STORE DATA
Timestudy Sheets in local shared-drive system,
doc control, database, etc…

Not on individual PC’s!

Enter data into IEDB 2.0 (coming in August 2019)

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 SUMMARY

 Engineered Work Standard

 Work Study

 Method: Process Flow Chart

 Measurement: Time Study

 Rating

 Personal Fatigue & Delay PF&D%

 Standard Time

 Data Storage

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 THANK YOU
Remember to visit the IE portal for the latest news and announcements
https://jabil.sharepoint.com/sites/IE/en-us/Pages/IEDivision.aspx

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