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Topic includes
- Method study- Objectives
- Procedure
- Selection
- Charts
- Explanation of all charts
Definition
Method study is the systematic recording and critical examination of the existing and proposed ways of doing work, as a means of developing and applying easier and more effective method and reducing costs.
Objectives, Procedure and Selection of Work for Method Study!
Always, the objective of method study is to simplify the job and develop more economical methods of doing it. Method study is systematic both in investigation of problem being considered and in the development of its solutions. It can be stated as one of most penetrating tools of investigation available to management.
Important objectives of method study are:
1) The improvement of processes and procedures.
(2) Factory and work place layout improvement.
(3) Improvement in the design of plant and equipment.
(4) Reduction in unnecessary fatigue and movements
5) Use of improved materials, machines and manpower.
(6) Better Working conditions.
While examining any problem, analyses should be done in a definite and ordered sequence. Usually the sequence is firstly defining the problems and obtaining all the relevant information regarding the problems. Then, there facts or information’s are examined critically. Then decision is taken and is acted upon. All this is always followed by routine checks.
So, the following seven steps constitute the basic procedure of method study:
1) Selecting the work to be studied.
(2) Obtaining all the relevant information’s or facts regarding the exiting method by direct observation.
(3) Examining these facts critically but impartially.
(4) Developing the most effective and practical method.
(5) Defining the new method so as to create its identity.
(6) Installing the new method.
(7) Maintaining this method by regular routine checks.
We will be discussing all these stages separately in coming pages.
Selection of Work:
There are certain factors which are to be taken into account while selecting the work for method study:
(1) Economic factors:
Only those jobs are selected which keep good economic importance. Jobs involving bottlenecks which hold up other production operations, operations involving repetitive work etc. are the works that are investigated and studied.
(2) Technical factors:
Availability of the technical knowledge with which study is to be carried out is an important consideration that is to be kept in mind while selecting the job. Take an example of a machine tool which in not running at a speed at which the efficiency is maximum.
(3) Human considerations:
Human reactions are always very difficult to predict. So, the experience of local personnel and conditions will reduce the problems. So, if the works selected involves the unpleasant features like dirty jobs or lifting of heavy weight are readily accepted by the workers.
Charts
Type # 1. Operation Process Chart:
This is a graphic representation of the sequence of all operations and inspections involved in the process. In this chart, all components or materials entry points are indicated by the horizontal lines and the processing of these materials are shown vertically. Operation process charts provide a compact overall view of the whole system of operations involved in the manufacture of a product.
In the process charts sequence of events are portrayed diagrammatically by means of a set of process chart symbols to help a person to visualise a process as a means of examining and improving it.
The basic symbols used in the process chart to record the various types of events are as follows
Types of Process Charts:
There are three types of process charts and they are:
i) Outline process chart.
ii) Two handed process chart.
iii) Flow process chart
i) Outline Process Chart:
An outline process chart is the first step to a detailed analysis of a process. It gives the overall view of the whole process by recording in sequence only the main operations and inspections. It uses only operations and inspection symbols.
ii) Two Handed Process Chart:
The two handed process chart gives a synchronised and graphical representation of the sequence of manual activities of the worker. It is called two handed process chart since it records the activities of the left hand and the right hand of the worker as related to each other. A time scale can also be provided on the chart. This chart is used for repetitive works of short duration.
iii) Flow Process Chart:
A flow process chart records all the events in sequence using process chart symbols and marks distance and time taken for completing an activity.
There are three types of flow process charts and they are:
i) Flow Process Chart (Men).
Type # 2. Flow Diagram:
A flow diagram is the simplest of all the devices in this class of technique. It is the plan view of a work to a certain scale and link diagram indicating the path followed by the object under study. It gives an overall view of an existing or proposed process and is used for making improvements. It shows the path followed by the material, man and equipment.
The steps involved in drawing a flow diagram:
i) The plan of the work area is drawn to scale.
ii) The relative positions of various facilities such as machines, stores, area of inspection and the like are marked.
iii) The actual path movements of a worker or material along with the direction of movement is indicated. For better understanding of different movements, different colours and process symbols may be used.
The above following shows a flow diagram in that material from stores move to place ‘A’ where one operation is performed. Thereafter the semi-finished product is sent to ‘B’ where another operation is conducted. After that it is moved to place ‘C’ wherein yet another operation is conducted. Then it is sent to place ‘D’ for inspection. Thereafter it is sent to place ‘E’ where it halts for some-time and finally goes out of the factor.
String Diagram:
A string diagram is a special form of flow diagram in which a string is used in place of lines to measure distance. This diagram is a layout drawing on which a length of string is used to record the extent as well as the pattern of movement of a worker or piece of equipment working within a limited area during a certain period of time. It is used to study where the journeys are irregular in distance and frequency, otherwise it will be difficult to see exactly what is happening.
It is used to investigate movement in the following situations:
1. When a group of operators is working.
2. When a single operator is attending several machines.
3. In processes where several sub-assemblies have to be moved to other assembly.
4. Where processes require the operator to be moved from one work place to another.
5. For checking the relative values of layouts.
Type # 3. Man-Machine Chart:
This chart explains graphically the activity of a man and machine he is attending with reference to a time scale. This study is undertaken to find what number of machine each worker can operate or how many workers can work on each machine.
This chart enables the management to minimise the idle time of the worker and to use the machines to their full capacity. For example, there are three workers and each worker is doing the same operations on machine. In that the time to set up a machine cycle is 0.50 minutes and machining time taken 0.75 minutes.
Type # 4. Left-Right Hand Chart:
This is also known as two handed process chart. It gives a synchronized and graphical representation of the sequence of manual activities of the worker. This type of chart is used to improve the motion sequence of an operator.
It is called two-handed process chart since it records the activities of the left hand and the right hand of the worker as related to each other in a two column chart by means of symbols aligned representing the simultaneous movements of both hands appear opposite to each other. The chart is used to minimize the unnecessary motions and to arrange the remaining motions in an economical way.
SIMO chart in motion Economy
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