L6 Workmeasurement PT

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MMS IV/PG IV/PT/dgm Date : 14.02.2009.

L6 - Work MeasurementThe "Process Focussed", mfg. units viz. automobiles, motor, etc.

where skilled labour cost form significant component of product cost,

"Work Measurement" technique form major contribution in

productivity. Although when plant is new, operation methods and

work content are perfect but as plant become old year wise products

are changing, plant layout is changing, workers, are changing etc. and

no attention is paid to method, sequence, efficiency, time etc.

This result into low productivity (due to improper method and

longer operation time). Hence methods and times are studied to

develop new method / modify to reduce time and work content. Thus

productivity is improved (restored towards original).


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Gilbreth developed "Method Study". Taylor developed "Time

Study". Both studies are called "Work Study" leading to "Higher

Productivity".

Taylor quoted "The greatest when each worker is

working is given definite task to perform in definite time in definite

manner.

Objectives of Work Study:

1) To develop new and better method of production.

2) To establish standard time for job.

3) To increase productivity and achieve best quality at minimum

cost.

4) To improve operational efficiency.

5) To improve industrial relations.

Method Study

Method study is systematic procedure to eliminate, combine or

reduce the work content of task, work simplification is usually done by

worker / supervisor after brief training whereas methods is usually

done by Industrial employer / professional trained staff (methodengineers).

Primary objective is to reduce time taken to perform task. Other

benefits are :

Elimination of part/ component.

Reduction in Energy consumption

Reduction ion Capital cost.

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Reduction in other expenses.

Procedure :

Step-by-step procedure is given below :

1) Select : Select operation worth improving, bottle neck, costly,

too much time & material, tools etc.

2) Record Motion : *

a) Get all facts about present method

b) Make (i) Flow chart (ii) Flow diagram etc.

iii) Man - machine chart

iv) Right & Left hand chart

c) Chart on actual case on job

* sometime motion picture is taken.

3) Analyse :

Challenge & analyse every detail

Try to eliminate

combine

simplify

change sequence

4) Develope :

Try out various suggestions, develop best way and make chart /

diagram of New method. Repeat step 2 & 3 suggest to

management.

5) Implement : Prepare procedure, diagram etc. and convince

workers to use.

Motion Economy :

a) Operation should be simple, easy and few motions.

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b) 2 hands start opertn. & end motion at same time.

c) 2 hands should be never idle (except during rest times)

d) Motion of arms & hands in opposite direction

e) Smooth continuous curve motion preferred

f) Tools, material near handles.

g) Gravity feed bin preferred

h) Drop delivery / ejectors for product.

Illustration : Casting & Buffing Tasks

Sr.No. Operation Therblig Remark

1. Hold 2 -2. Grasp 3 -3. Release 1 -4. Transport 5 Activity5. Operate 2 -

Work Measurement

While method study is standardising of work, work measurement

is establishing work content of job. Hence after method study only

work measurement should be taken-up.

Definition : "Work measurement is defined as the application of

techniques designed to establish the work content of a specified task

by determining the time required for carrying out the task defined

standard of performance by qualified worker.:

Qualified Worker : "A qualified workers is one who is accepted as

having the necessary physical attribute, possessing required

intelligence, education and having acquired necessary skill and

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knowledge to carry out the work in and to satisfactory standard of

safety, quantity & quality."

Work content in job may be expressed in minutes per unit (or

hours / unit). It is called "standard time". It gives human

effectiveness. Also useful for labour standard & for planning &

controlling operations.

Objectives :

i) Improved Planning & control of operation.

ii) Efficiently manning plant.iii) Good basis for labour performance

iv) Good basis for cost control

v) Sound basis for incentive scheme

Techniques of Measurement :

1) Direct time Study (Stop watch)

2) Work sampling

3) Pre determined motion time system (PDMTS)

4) Synthesised method

Measurement Procedure :

Break job into elements and record observation time for each

element.

Illustration : A worker is doing a job of punching a hole in metal plate

by operating press tool machine. Various elements of job & their

observed times are given below in table. compute standard time for

the job.

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(in minutes)

Sr.No. Element Obs. Time Remarks

1. Grasp Plate 0.2 from stock2. Transport Plate 0.33. Load Machine 0.2 On Press tool4. Operate Start 0.15. Pull out plate 01.6. Transport 0.3 To finished

stock7. Release plate 0.1

Total Observed time = 0.13 Minutes

Use Rating factor @ 1.2 = 0.146 Minutes

Add. relax allow @ 10% = 0.1606 Minutes

Add cont. allow @ 10% = 0.1767 Minutes

Thus Standard Time is = 0.1767 Minutes

1) Direct study : In this study approach, Industrial Engr. /Method Engr. stand in front of actual operation done by worker

and measure time by stop watch. No. of observation are taken

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for operation under study as well as rest all operations in

completing task.

a) Avg. Time (AT) = Total time of OperationNo. of Observation

At (for grasp) = 0.2 min. (Ref. Pg. 5)

b) Normal Time (NT) = Performance Rating x AT

= (120%) x 0.2

= 1.2 x 0.2

= 0.44 min.

c) Personal, Fatigue & Delay Allowance

PFD = 120%

ST = NT (1 + PFD )

100

= 0.44 (1 + 120 )

100

= 0.44 (2.2)

= 0.968 Minutes

Thus standard time for grasping plate is 0.968 minutes.

Similarly ST for operate Load, Pull-out, release, transport etc. is

worked out. Sum of all is total work content i.e. standard time

for task of plate punching tool.

2) Work Sampling :

In this method large nos. of observation are taken for particular

operation / method. Proportion (p) is worked out as follows :

p = No. of obstn. (working)Total No. of observation

Record No. of units produced ( ) and total time (T) for study.

Avg. Time = AT = Study time x (p)No. of units produced

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Estimate NT by per. rating & std. time by PFT to get standard

time (ST).

Illustration :

A study was made on factory consisting of 130 machines for

determining average lubrication time required.

Data : Obsts. = 5,000 (Study time = 110 hrs.)

M/c. lubricated = 400 occasion

PR Factor = 90%

PFD Factor = 15%

Solution :

Avg. Lubri. time (AT) = Study Time x (P)

No. of units

= (110 X 60) X (400)

5000AT = 4.03 Min. /

NT = (PR) (AT) = (0.9) (4.03)

= 3.655 Min/

Std. Time (ST) = NT (1+ PFD/100)

= 3.655 (1+15/110)= 4.2 Minutes

3) Predetermined Time Motion Study (PDTMS) :

From the recording of motion picture of similar task elements, a

motion time film is produced. Basic motions like grasp, store,

transport, release, position etc. are given std. time and finally

standard time for complete task is worked out. Management &

workmen union study and conclude for agreement of standard

Task time for various jobs of mfg. firm.

Illustration :

1) Method Time Measurement System has following 3 models.

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MTM - 1

MTM - 2

MTM - 3

2) Work Std. Factory has PDTMS.

3) Macro Standard Data has PDTMS.

4) Synthesised Method : It uses a mixer of previous stop time

watch data and PDTMS data for similar job and synthesis

(compute) std. time.

NOTE : MUDA The elements of task which are non-value added

are called "MUDA" or wastage. MUDA should be minimised.

REFERENCE :

1) Production Mgt. by Aswathapa & Bhatt.

2) Productivity Engg. by David Sumanth.

dgm: 14.2.09

******

MMS IV /PG IV/PT/dgm Date : 10.2.2009

L5 - VALUE ANALYSIS & ENGG.

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"Value Analysis" is improving productivity by reducing cost of

product (existing) - using cheaper component / part or elimination. VA

is the partial productivity by material input reduction.

Value Engg. is redesigning part / component or sub-assembly of

existing product to increase functional utility by consumer but with

attempt to retain input costs. Thus cost to benefit ratio is improved

which enhance the sales / profit. Thus VE is productivity increased

by product design improvement. VA & VE productivity improvement

equation are as follows :

VA Productivity = Fun. Value - (I)

Input Cost

VE Productivity = Fun. Value - (II)

Input Cost

Value Analysis : In this method, parts/components of products

(Bom) are listed down in descending order of cost and compared with

functio0nal value. Highest ratios are attempted / searched for cost

reduction (thereby improving productivity (Eqn. (I) above). Annexure

(I) analysis cost function of domestic LPG cylinder (14.5 Kg. Cooking

Gas). It recommend VA on cylinder and knob which has highestcost - function ratio. Since this ratio forming 50 - 65% of RM in

product cost, if 4% is reduced, then it will generate about 2% of profit

for organization.

Illustrations :

i) Pharma products started using plastic bottles in place of glass

viz. "Glycodin Cough Syrup: of 50 ml / 100 ml (Alembic make

Vadodara). Result of cheaper substitute material / search.

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ii) Engg. & FMCG products replace steel / brass gears by plastic

gears viz. Mixer, xerox machine, circuit breaker etc. (cheaper

substitute material).

iii) Automobile parts using cheaper alloys.

iv) Pharma products supplied without paper carton box (part

elimination)

Purchase dept. of Mfg. firm continuously negotiate cost reduction

with supplier / vendors for "Fair Price". Sometimes also involves

design engineer. Sometime VA is referred as "Cost Analysis". It

maintains Data Bank of Vendors and continuously upgrade with

search for substitute material is done in Exhibitions, Trade Fairs,

Import Data Statistics (Govt. Publication) etc.

Value Engg. : Indian economy becoming "Free Economy" from 1992

due to signing of GATT, cost reduction & quality improvement has

acquired paramount importance in mfg. & service sectors. Thus

functional improvement of * product and if possible for decreasing

input. Product - productivity improves leading to improved sales /

profit. VE is done at product maturity stage of PLC curve or a new

product launching stage. VE was developed during W W II by Miles.

Also US Navy contributed in cost reduction.

* A product is an article in commerce for exchange of functional

utility for some value.

Types of Functional Values:

Type

No.

Function Type Product Remark

1. a) Use Function

b) Aesthetic Function

Trekker

Shoes

Use - Protect feet

Aesthetic - Please user

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2. a) * Primary Function

b) Secondary Function

LPG

Cylinder

Prime -Hold high press. gas

Second - Facilitate smooth

supply to gas stove.

3. a) Higher Order Functionb) Lower Order Function

Torch Higher Function -facilitate viewing

Lower Function -

light bulb provide cells

* Sometimes unwanted functions are required viz. Overhead

projector uses incadecent lamp (say 100 W) and produces heat

which calls for small cooling fan. Cooling function is unnecessary

secondary function.

For VE, Anglo American council of productivity suggest 10 questions

as per Annexure I.

Annexure II describes Case II of Value Engg. done on Ball Pen. It list

down parts and their function. Then function of part are analysed for

modification / elimination. Case recommends followings :

i) combine Head & Cylinder (Integrate)

ii) Eliminate rings (Aesthetics)

Savings and expenses are as follows:

Sr.

No.

Item Discovery Savings New

Exps.

Remark

1. Rings (2) Eliminate Yes -- --2. Cylinder +

Cap

Integrate Yes Yes Amortise

new die

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cost on

quantity.

In this case Value Engineering is done on existing product design bymodifying, but without sacrificing functional value, quality, reliability.

Value Engg. team consists of Design Engineer, R & D Engineer,

Marketing Engineer & Purchase Manager.

Annexure IV describe a case for VE done on Electronic Equipment.

Engineer's cost involved was 80 man hrs. @ $ 2 and $ 10,000design Engg. drawings, documents etc.

The discovery was eliminating 2 holes and replacement of Diecast by

plastic , giving a total $ 2.5 Unit Savings. This gave about 13%

Productivity improvement.

Illustration :

i) Intel enhanced performance function of new cheap launching

but at cheaper rate than earlier version.

Productivity = Higher Performance

Lower Cost

Due to product based higher productivity, Sales / Profit is considerably

enhanced.

ii) Maruti Udyog Ltd., Gurgaon did Value Engg. for new small end

car keeping in mind other small cars like Fiat, Ambassador,

Dolphine etc. Co. engineered high performance car like high

fuel efficiency, 3 cylinder engines, Japanese parts &

Engineering, very competitive prices, excellent services all over

country etc. Such a excellent Value Engg. of new car (Maruti

800) made successful launch leading to rapid introduction and

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growth of product which resulted into established brand giving

loyal customers for many years to come.

While doing a Value Engg. of a new product, following aspects

are specially kept as objective.

a) Product Simplification:

i) Minimize Models

ii) Reduction in range of Material and components/ parts and

reducing in complexity of methods & process.

b) Product Standardization:

Product standardization is a systematic effort on the part of

design engineer, Industrial Engineer and Marketing Manager to

create a product- mix to minimize manufacturing, distribution,selling and maintenance cost.

c) Research & Development:

Since productivity is continuous and competition process for

survival and growth of organization , time span and fund

allotment should be committed by organization.

References :

i) Operation Management (PP 20.3) by Chary.

ii) Operation Management (PP 119-21) by Gaither.

iii) Productivity Engg. (PP 433-39) by David Sumanth.

iv) Productivity Technique (PP 91-105) by Dr.Salunke

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L6 Workmeasurement PT

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