Time and Motion Study & Work Measurement

Transcription

1 Department of Industrial Engineering Time and Motion Study & Work Measurement 1

2 Definitions Motion study or work methods design:for finding the preferred method of doing work. That is, the ideal method or one nearest to it. Time study or work measurement: for determining the standard time to perform a specific task. Time and Motion Study & Work Measurement The fundamental tools that result in increased productivity are: methods, time study standards, and work design. All aspects of a business or industry - sales, finance, production, engineering, cost, maintenance, and management provide areas for the application of methods, standards, and work design. 2

3 Time and Motion Study & Work Measurement (cont.) Also, they are creative in improving existing methods and products to help the company attain leadership in its product line. In this activity, good labor relations may be maintained through establishing fair labor standards. Methods, standards, and work design and measurement offer real challenges. Industries with competent engineers, business administrators, industrial relations personnel, specially trained supervisors, and psychologists all using methods, standards, and work design techniques are certainly better able to meet competition and better equipped to operate profitably. Time and Motion Study & Work Measurement (cont.) If the production department is considered the heart of an industrial enterprise, the methods, standards, and work design activity is the heart of the production group. They use initiative and creativity to develop efficient tooling, worker and machine relationships, and workstations on new jobs in advance of production. Also, they are creative in improving existing methods and products to help the company attain leadership in its product line. In this activity, good labor relations may be maintained through establishing fair labor standards. 3

4 Time and Motion Study & Work Measurement (cont.) The objective of the manufacturing manager is to produce a quality product, on schedule, at the lowest possible cost, with a minimum of capital investment and a maximum of employee satisfaction. The focus of the reliability and quality control manager is to maintain engineering specifications and satisfy customers with the product s quality level and reliability over its expected life. The production control manager is principally interested in establishing and maintaining production schedules. Time and Motion Study & Work Measurement (cont.) The manager of methods, standards, and work design is mostly concerned with combining the lowest possible production cost with maximum employee satisfaction without sacrificing workplace safety. The maintenance manager is primarily concerned with minimizing facility downtime due to unscheduled breakdowns and repairs. Figure illustrates the relationship of the manager of the methods, standards, and work design department to the staff and line departments under the general manager. 4

5 Islamic University of Gaza -Palestine Methods engineers Methods engineers use a systematic procedure to develop a work center, produce a product, or provide a service. Select the project. Typically, the projects selected represent either new products or existing products that have a high cost of manufacture and a low profit, experiencing difficulties in maintaining quality and are having problems meeting competition are projects for methods engineering. Get and present the data. Assemble all the important facts relating to the product or service. These include drawings and specifications, quantity requirements, delivery requirements. Islamic University of Gaza -Palestine Methods engineers (Cont.) Analyze the data Utilize the primary approaches to operations analysis to decide which alternative will result in the best product or service. These primary approaches include: purpose of operation, design of part, tolerances and specifications, materials, process of manufacture, setup and tools, working conditions, material handling, plant layout, and work design. Develop the ideal method Select the best procedure for each operation, inspection, and transportation by considering various constraints associated with each alternative, including productivity, ergonomics, and health and safety implications. 5

6 Islamic University of Gaza -Palestine Methods engineers (Cont.) Present and install the method Explain the proposed method in detail to those responsible for its operation and maintenance. Consider all details of the work center, to insure that the proposed method will provide the results anticipated. Develop a job analysis Conduct a job analysis of the installed method to insure that the operators are adequately selected, trained, and rewarded. Establish time standards Establish a fair and equitable standard for the installed method. Islamic University of Gaza -Palestine Methods engineers (Cont.) Follow up the methods. At regular intervals, audit the installed method to determine if the anticipated productivity and quality are being realized, whether costs were correctly projected, and whether further improvements can be made. WORK DESIGN As part of developing or maintaining the new method, the principles of work design must be used to fit the task and workstation ergonomically to the human operator. 6

7 Islamic University of Gaza -Palestine STANDARDS Standards are the end result of time study or work measurement. This technique establishes a time standard allowed to perform a given task, based on measurements of the work content ( that is time taken to manufacture the product or to perform the operation if the design or specification of product or service provided were perfect) of the prescribed method, with due consideration for fatigue and for personal and unavoidable delays. Time study analysts use several techniques to establish a standard: a stopwatch time study, computerized data collection, standard data, predetermined time systems, work sampling, and estimates based on historical data. Islamic University of Gaza -Palestine STANDARDS Time study analysts use several techniques to establish a standard: a stopwatch time study, computerized data collection, standard data, predetermined time systems, work sampling, and estimates based on historical data. The resulting standards are used to implement a wage payment scheme. In many companies, particularly in smaller enterprises, the wage payment activity is performed by the same group responsible for the methods and standards work. Production control, plant layout, purchasing, cost accounting and control, and process and product design are additional areas closely related to both the methods and standards functions. 7

8 Islamic University of Gaza -Palestine OBJECTIVES OF METHODS, STANDARDS, AND WORK DESIGN The principal objectives of methods, standards, and work design are: (a) Increase productivity and product reliability safely (b) to and to decrease unit cost HISTORICAL DEVELOPMENTS FREDERICK W. TAYLOR Frederick W. Taylor is known as the father of scientific management and industrial engineering. Islamic University of Gaza -Palestine FREDERICK W. TAYLOR (Historical Review) He is the first person to use a stopwatch to study work content. Many years later, he established his four Principles of Scientific Management: 1. Develop a science for each element of a person s work. 2. Select the best worker for each task and train that worker in the prescribed method. 3. Develop a spirit of cooperation between management and labor in carrying out the prescribed methods. 4. Divide the work into almost equal shares between management and labor, each doing what they do best. 8

9 F.W. Taylor and Scientific Management Scientific Management The systematic study of the relationships between people and tasks for the purpose of redesigning the work process for higher efficiency. Defined by Frederick Taylor in the late 1800 s to replace informal rule of thumb knowledge. Taylor sought to reduce the time a worker spent on each task by optimizing the way the task was done. Frank and Lillian Gilbreth Refined Taylor s work and made many improvements to the methodologies of time and motion studies. Time and motion studies Breaking up each job action into its components. Finding better ways to perform the action. Reorganizing each job action to be more efficient. Also studied worker-related fatigue problems caused by lighting, heating, and the design of tools and machines. 9

10 Islamic University of Gaza -Palestine FRANK AND LILLIAN GILBRETH (Historical Review) Frank and Lillian Gilbreth were the founders of the modern motion study technique, which may be defined as the study of the body motions used in performing an operation, to improve the operation by eliminating unnecessary motions, simplifying necessary motions, and then establishing the most favorable motion sequence for maximum efficiency. They developed theories of efficient motions through defining terminology of the entire range of manual motions. These 17 elementary subdivisions of motion, later engineers named a short word, therblig. Islamic University of Gaza -Palestine HENRY LAURENCE GANTT (Historical Review) Henry Laurence Gantt invented the task and bonus system or earned-hour plan. Rather than penalizing the less proficient worker as Taylor did with his multiple piecework plans, Gantt advocated a livable wage with a sizable bonus for performance over 100%. While Taylor emphasized the analytical and organizational aspects of work, Gantt was more interested in operator selection, training, and motivation. 10

11 Islamic University of Gaza -Palestine RALPH M. BARNES (Historical Review) Dr. Barnes was one of the first and best-known professors of engineering in the field of work measurement. His achievements included writing the longest published text on work measurement, a thorough description of the Gilbreths micromotion study, time study, and the procedure for work sampling. He conducted numerous methods studies of activities with motion picture cameras and developed rating films for training time study technologists. Four Principles of Scientific Management Principles to increase efficiency: 1. Study the ways jobs are performed now and determine new ways to do them. Gather detailed time and motion information. Try different methods to see which is best. 2. Codify the new methods into rules. Teach to all workers the new method. 3. Select workers whose skills match the rules. 4. Establish fair levels of performance and pay a premium for higher performance. Workers should benefit from higher output 11

12 Problems with Scientific Management Managers frequently implemented only the increased output side of Taylor s plan. Workers did not share in the increased output. Specialized jobs became very boring, dull. Workers ended up distrusting the Scientific Management method. Workers could purposely under-perform. Management responded with increased use of machines and conveyors belts. Islamic University of Gaza -Palestine ORGANIZATIONS Technical organizations have contributed much toward bringing the science of time study, work design, and methods engineering up to present-day standards. The Institute of Industrial Engineers (IIE) was founded in 1948 with the purposes of: maintaining the practice of industrial engineering on a professional level; fostering a high degree of integrity among the members of the industrial engineering profession; 12

13 Islamic University of Gaza -Palestine ORGANIZATIONS (cont. ) encouraging and assisting education and research in areas of interest to industrial engineers; promoting the interchange of ideas and in formation among members of the industrial engineering profession (e.g., publishing the journal IIE Transactions); In the area of work design, the first professional organization, the Ergonomics Research Society, was founded in the United Kingdom in It started the first professional journal, Ergonomics, in Currently, there are well over 5,000 members organized in 20 different technical groups. Islamic University of Gaza -Palestine PRESENT TRENDS Practitioners of methods, standards, and work design have come to realize that such factors as age, health and well-being, physical size and strength, training attitudes, job satisfaction, and motivation response have a direct bearing on productivity. Today s practitioners must use the humane approach. They must be well versed in the study of human behavior and accomplished in the art of communication. They must also be good listeners, respecting the ideas and thinking of others, particularly the worker at the bench. 13

14 Islamic University of Gaza -Palestine PRESENT TRENDS Today, there is a greater intrusion by the government in the regulation of methods, standards, and work design. For example, military equipment contractors and subcontractors are under increased pressure to document direct labor standards as a result of MIL-STD 1567A Similarly, in the area of work design, Congress passed the OSH Act establishing the National Institute for Occupational Safety and Health (NIOSH), are search agency for developing guidelines and standards for worker health and safety, and the Occupational Safety and Health Administration (OSHA) an enforcement agency to maintain these standards. Operation Analysis Approach-2 Set-up and Tools Reduce set-up time: SMED Material Handling Handling equipment Ergonomic principles Lay-out 14

15 Operation Analysis Approach-1 Method analysis Eliminate, simplify, or combine operations Design analysis Reduce the number of parts Design for manufacturability and assembly Manufacture sequence Rearranging operations Mechanizing manual operation 15

16 The Four Principles of Motion Economy 1. Reduce the Number of Motions Eliminate or reduce the number of motions 2. Perform Motions Simultaneously q Design improvements in the methods and tools which allow both hands to be used at the same time The Four Principles (cont d) 3. Shorten Motion Distances Reduce - walking, reaching, stretching, squatting and turning, etc. 4. Make Motion Easier q Work should be smooth and rhythmical, reduce fatigue and promote safety 16

17 Use of the Human Body Both hands should start and finish the operation at the same time. Reduce idle time for either or both hands Arm motions should be symmetrical Employ curved movements during the operation Employ rhythmical standard operation Ensure a similar focal point for tools, materials, etc. Arrangement of the Work Place Use fixed positions for tooling and parts to allow habits to form easily Use gravity feeding to ensure a common pickup point Position parts, materials and tools to enable sequential use Use ejector systems or drop deliveries, so the operator has minimal effort to pass on parts to the next operation Benches and chairs should be at the correct working height to avoid interrupted motions All equipment should be within the maximum work area 17

18 Design of Tools and Equipment Eliminate the need to use one hand purely to hold a part Use combination tools Use counterbalances on heavy tooling Ensure handles on tools are designed to use maximum hand contact Place tooling in the most convenient positions Separate part supplies should be used for two operators. Tools should be placed to enable immediate use Provide chutes for access of parts, and components in/out of the workplace 5 S Seiri, Seiton, Seiso, Seiketsu, Shitsuke Sort, Clean, Set in order, Standardize, Progress 18

19 PokaYoke Mistake proofing A manufacturing technique of preventing errors by designing the manufacturing process, equipment, and tools so that an operation literally cannot performed incorrectly Excuses I like the way I am doing it now. It's too radical a change. I tried it once and didn't like it. It sounds like a production line. It won't work in our office. I think we should look into it further before we act. It won't pay for itself. I know a fellow who tried it. We've always done it this way. 19

20 Principles of Motion Economy Both hands should work at the same time. The hands should work in opposite symmetrical directions. Each hand should go through as few motions as possible. The work place should be designed to avoid long reaches. Avoid using the hand as a holding device. Work Measurement Basics Objective: Labor Standards/Time Standards Time per Cycle of a Job Timing: Comes after methods analysis/motion study Focus: Proper Method Average Pace Average Worker 20

21 Work Measurement Uses Estimating Work Force/Capacity Requirements Costing Production Operations Worker Performance/Wage Incentive Systems Scheduling Production Work Measurement Techniques Stopwatch Time Study Compiled from Observations Historical Experience Rough Estimates-Tables/ Formulas Work Sampling Statistical Estimate-Percentage of Occurrence Predetermined Time Standards Commercial Systems Standard Tasks/Movements 21

22 Work Measurement Motion study is the systematic study of the human motions used to perform an operation. Work measurement: Measures time requirement to make a product Time standards: The time required for a trained worker to perform a given task using a prescribed work method with normal effort and skill. Uses of standards Uses of standards % Estimating and cost 89% Incentive compensation plans 59 Production scheduling 55 Performance appraisal 41 Staffing & capacity plans 2 Major Methods of Work Measurement Type of Task Very short interval, highly repetitive Short interval, repetitive Task in conjunction with machinery or other fixed processing time equipment Major Methods Film analysis Stop watch time study or predetermined data Elemental data or subjective estimate Infrequent work or work of a longwork sampling or subjective cycle time estimate 22

23 The Critics of Work Measurement UPS has 1000 industrial engineers (out of a work force of 152,000) set standards for a myriad of closely supervised tasks. Productivity and profits are high. Time study is a dark-ages technique, and it s dehumanizing to track someone around with a stopwatch. Vice President, H.B. Maynard & Co. Time Study Sheet 23

24 Elemental Standard Time Data Develop tables of performance times for operations that are common to many applications. Avoids the need for separate time studies. Motion Study Motion study -systematic study of human motions used to perform operations Micro approach, one worker in workstation. 24

25 Motion study & Motion Study Techniques Motion study - systematic study of human motions used to perform operations, Micro approach, one worker in workstation Motion study principles - guidelines for motion-efficient work Analysis of therbligs - breaking job into elemental motions Micromotion study - use of motion pictures and slow motion to study minute motions Charts Done before work measurement Predetermined Motion-Time Data Systems Uses historically developed data for time required for basic body movement, elements of operation, or even an entire operation. Very useful in estimating new product cost. Procedure Divide total task into elements. Rate the difficulty of each element. Look up tables for the time allowed for each element. Add all element times together. Systems available Methods time measurements (MTM). Basic motion time study (BMT). Motion time survey (GE). Work factor. 25

26 The MTM Predetermined Motion-Time Data System 26