Motion and Time Study

Transcription

1 Motion and Time Study WORK SYSTEMS 1 Historical Figures Related to Work Industrial Revolution (1770 s) o JamesWatt Wtt( ) steam engine 4 1

2 Historical Figures Related to Work Henry Maudslay ( ) o Screw cutting lathe (1800) o Standardization of screw thread sizes o Interchangeability o The first bench micrometer capable of measuring to one ten thousandth of an inch ( in 3 µm). 6 Eli Whitney ( ) Cotton gin (1793) 8 2

3 Eli Whitney ( ) Muskets(Interchangeable parts manufacture) o promotion and popularizing o produces 10,000 muskets for the US government o Standard parts o Special tools, fixtures etc. o Unique products replaces customfabricate products 9 Henry Ford ( ) o Mass production o Assembly line o Model T for less than $500 in 1916 Movie 1 Movie

4 Frederick W. Taylor ( ) Father of Scientific Management (late 1800s) & IE First to use a stop watch (father of time study) 1. Motion study Finding the best method to perform a given task 2. Time study To establish work standards for a job 3. Extensive use of standards in industry 4. Piece rate systems & similar labor incentive plans 5. Data collection, record keeping, and cost accounting factory operations. 11 Taylor s Shoveling Experiment before after study No people lb/shovel Bonus no yes Work unit teams individual Cost/ton 7 8c 3 4c A saving of $78,000/year 12 4

5 Pig iron handling Yard workers who loaded pig irons from storage yard to freight cars were not using the best method. Work too hard ( had to rest for too long) Daily wage was $1.15 (1898) Averaged 1.5 tons per day Schmidt ($1.85) Improvements (pick up, carry, drop off, more frequent but shorter breaks) 47 tons per day 13 Frank ( ) & Lillian Gilbreth ( ) Father (mother) of motion study All works are composed of basic motion elements (therbligs) There is one best method to perform a certain task. Cheaper by the Dozen o Motion study (finding the best method to perform a task) o Time study to establish work standards for a job o Use of standards in industry o Labor incentives (bonus payments for higher outputs) o Use of data collection, record keeping, cost accounting o The objective is to improve the (labor) productivity 14 5

6 Bricklaying Bricklayer assigned to teach him laid bricks in three different ways: o Normal way, when working fast, when instructing Other bricklayers used other (different )methods One best way to accomplish bricklaying All bricklayers should use it Reduced number of steps required to lay one brick by 70% Adjustable bricklayer s scaffold 15 Work Is our primary means of livelihood Serves an important economic function in the global world of commerce Creates opportunities for social interactions and friendships Provides the products and services that sustain and improve 17 6

7 The Nature of Work Work is an activity in which one exerts physical and mental effort to accomplish a given task or perform a duty Task or duty has some useful objective Worker applies skills and knowledge for successful completion The activity has commercial value The worker is compensated 18 Work (Physics Definition) The displacement (distance) that an object moves in a certain direction multiplied by the force acting on the object in the same direction. W=Fμd (Newton meter) Units of measurement: o Newton meters (N m) in the International System of Units (metric system) o Foot pounds (ft lb) in U.S. customary units Work is more than muscular applications. Combination of physical and cognitive work. 19 7

8 The Pyramidal Structure of Work Work consists of tasks o Tasks consist of work elements Work elements consist of basic motion elements 20 Task An amount of work that is assigned to a worker orfor which a worker is responsible Repetitive task as in mass production o Time required = 30 seconds to several minutes Non repetitive task performed periodically, infrequently, or only once o Time required usually much longer than for repetitive task 21 8

9 Work Element A series of work activities that are logically grouped together because they have a unified function in the task Example: assembling a component to a base part using several nuts and bolts o Reaching for a part o Grasping it o Attaching it to a base part Required time = six seconds or longer A work element consists of multiple basic motion elements 22 Basic Motion Elements Actuations of the limbs and other body parts Examples: o Reaching for an object o Grasping the object o Moving the object o Walking o Eye movement 23 9

10 Pyramidal Structure of Work Extended to a worker s career 24 Importance of Time In many human endeavors, time is of the essence o In sports o In daily living o In business and industry o In work 25 10

11 Time in Business and Industry New product introduction o Shortest time > > most profits Product cost o Labor hours represent a significant portion of total manufacturing cost Delivery time o Supplier with shortest delivery time is selected o Overnight htdli delivery o Competitive bidding: Production scheduling 26 Importance of Time in Work Time is the most frequently used measure of work o How many minutes or hours are required to perform a given task? Most workers are paid by the time they work o Hourly wage rate o Salary Workers must arrive at work on time Students must arrive at class on time Labor and staffing requirements computed in units of time 27 11

12 As a physical entity Work System Defined A field of professional practice 28 A Work System as a Physical Entity As a physical entity, a work system is a system consisting of humans, information, and equipment designed to perform useful work Contributes to the production of a product or delivery of a service 29 12

13 A Work System as a Physical Entity Examples: o Worker operating a machine tool in a factory o Robotic welding line in an automobile plant o Parcel service agent driving a delivery truck to make customer deliveries o Designer working at a CAD workstation o A receptionist answering incoming phone calls 30 Work System Defined as a field of professional practice As a field of professional practice, work systems include: A. Work methods B. Work measurement C. Work management 32 13

14 Work System Defined as a field of professional practice Work methods jobs involving human work activity analysis and design of tasks and o Motion study (physical motion, tools, & work place layout) o Operations analysis & methods engineering (less restrictive and include the analysis and design of complex processes: material and information) 33 Work System Defined as a field of professional practice Work measurement analysis of a task to determine the time that should be allowed to perform the task (standard time) Product costs Worker performance Worker requirements Standard time o (Time=Money) How long it takes to accomplish a given work 34 14

15 Work System Defined as a field of professional practice Work management organizational and administrative functions that must be accomplished to achieve high productivity and effective supervision of workers o Organizing gworkers o Motivating workers o Evaluating jobs o Evaluating performances o Compensating workers (labor wages) 35 Jobs and Occupations Four broad categories that reflect the work content and job function: 1. Production workers make products 2. Logistics workers move materials, products, or people 3. Service provide a service, apply existing information and knowledge, communicate 4. Knowledge workers create new knowledge, solve problems, manage 37 15

16 Comparisons: Industries and Workers 1. Production workers o Making products o Manufacturing, construction, agriculture 2. Logistics workers o Moving materials, products, people o Transportation, distribution, material handling 38 Comparisons: Industries and Workers 3. Service workers o Providing service, applying existing information knowledge, communicate o Banking, retail, government, health care 4. Knowledge workers o Creating knowledge, solving problems, managing o Management, engineering, legal, consulting, education 39 16

17 Comparisons: Worker Discretion Refers to the need to make responsible decisions and exercise judgment in carrying out duties of the position ii Jobs that are highly standardized and routine require minimum worker discretion o Typical for production and logistics workers Jobs in which workers must adapt their behavior in response to variations in the work situation require high discretion o Typical for service and knowledge workers 42 17