1st Day
What is Work-study?
Work-study is the systematic
examination of the methods of carrying activities so as to improve the
effective use of resources and to set up standards of performance for the
activities being carried out.
Work-study |
Method
study Work
measurement.
Work
place engineering Time
study
Motion
economy G.S.D
Sew easy 2005.
Capacity Study.
Historical data. Analytical estimating.
Minimum work
place.
Maximum work
place.
Why it is valuable?
1)
It
is a direct means of raising productivity involving little or no expenses.
2)
It
is systematic, simple, and consistent in based on the handling of facts.
3)
It
ensures that no factor affecting the efficiency of operating is over looked.
4) It is a tool, which can be applied
universally.
5)
It
is the most penetrating tools of investigation available to management.
6)
It
is relatively cheap and easy to apply.
Objectives of work-study:
1)
Lower
cost.
2)
Increase
productivity.
3)
Increase
profitability.
4)
Increase
jobs security.
5)
To
make the work easier.
6)
Establish
fair task for every one.
7)
Check
achievement against standard.
Work Study & IPE:
Work-study
is the part of Industrial & production engineering. This is like the
cricket game where the methods are improved.
2nd Day
What
is Method study?
Method
study is the systematic recording and critical examination of existing and
proposed ways of doing work as a means of developing and applying easier and
more effective methods and reducing cost.
It is a systematic recording and
critical examination of ways of doing things in order to make improvement.
(In
a sort letter “ to reduce the cost, which examination/system are going to set
up to developing and applying easier and more effective methods”.)
Objectives of method study: -
1)
For
better design of plant equipment and buildings.
2)
Improve
layout of factory and office.
3)
Higher
standard of safety and health.
4)
To
improve the flow of work.
5)
To
get the better quality.
6)
Effective
materials handling.
7)
To
improve the proper utilization of resources.
8)
To
get maximum output.
9)
To
improve administration.
10)Waste reduction.
Why should method study come first?
All
the techniques of work-study are inter-connected and any separation is only for
convenience of discussion.
Work place engineering
Minimum working area
Maximum working area
Motion Economy:
Selecting the work to be
studied:
When you
are going to carry out a method study, before selecting the job you have to
consider the following:
1)
Economic
or cost effective consideration,
2)
Technical
consideration,
3)
Human
consideration.
Economic consideration: -
It is obviously a waste
of time to start or to continue a long investigation if the economic importance
of a job is small, or if it is one that is not expected to run for long section
that should always be asked will it pay to be in a method study of this job or
will it pay to continue this study obvious choice for study are:
1)
Key
profit generating or costly operation or ones with the largest waste rates.
2)
Bottlenecks,
which are holding, up other production operation.
3)
Operations
involving repetitive work a great deal of labors and ones that are lightly to
run for a long time.
4)
Movement
of materials over a long distance between workstation those involving the use
of a relatively large production of labor or which require repeated handling of
materials.
Technical consideration:
One
of the important consideration is the desire by measurement to acquire were
advance technology whether in equipment or in process. This management way wants
to computerize its office paper work or its inventory system, or to introduce
automations in the production operation before such steps are taken, a method
study can point out the most important needs of the enterprise in this respect.
Human consideration:
Certain
operation is often a cause of dissatisfaction by workers. They may induce fatigues or monotony or may be waste or
clumsy to operate the level of satisfaction should point to needs for method
study. This an operation such may be perceived as effective by management may,
or the other hand generate a great deal of resentment by workforce if such
operations are addressed by work study specialized as part of an overall work
study programs. The benefit of work-study can become more appearance to the
work force.
3rd
Day
The procedure of method study: -
1)
Select:
The work to be studied and define its boundaries.
2)
Record:
The relevant factors about the job by direct observation and collect such
additional data as may be needed from appropriate sources.
3)
Examine:
The way the job is being perform and challenge its purpose, place, sequence and
method of performance.
4)
Develop: The most practical, economic and
effective method drawing on the contributions of those concerns.
5)
Evaluate:
Different alternative to develop a new improve method comparing the cost
effectiveness of the selected new method with the current method of
performance.
6)
Define:
The method as a result in clear manner and presenting to those concerns that is
management, supervisor, and workers.
7)
Install: The new method as a standard practice
and trained the process involved in applying it.
8) Maintain: The new method an
introduce control procedures to prevent a drifting back to the previous method
of work.
The principle of motion economy:
1)
Use
of human body.
2)
Arrangement
of the work place.
3)
Design
of tools and equipment.
Use of human body: -
a)
The
two hands should begin and complete their movement at the same time.
b)
The
two hand should not be idle at the same time accept during the period of rest.
c) Motion of the arm should be
symmetrical and in opposite directions should be simultaneously.
d) Hand and body motion should be made
at the lowest specifications at which it is Possible to do the work
satisfactory.
e) Continuous curve movements
are to be preferred to straight-line motions involving sudden and sharp changes
in direction.
f) Ballistic (free swinging)
movement is faster, easier and more accurate than restricted movement.
g) “Rhythm” is essential to the
smooth and automatic performance of a repetitive operation. The work should be
arranged to permit easy and natural rhythm when ever possible.
h) Work should be arranged so that eye movements
are confined to a comfortable area without the need for frequent changes of
focus.
Classification
of movement: -
Class
|
Pivot
|
Body
members moved
|
1
|
Knuckle
|
Finger
|
2
|
Wrist
|
Hands,
finger.
|
3
|
Elbow
|
Forearm,
hands, finger.
|
4
|
Shoulder
|
Upper
arm, forearm, hands, finger.
|
5
|
Trunk
|
Torso,
upper arm, forearm, hands, finger.
|
Arrangement of the work place: -
1)
Definite
and fixed stations should be provided for all tools and materials to permit
habit formation.
2)
Tools
and materials should be repositioned to reduce searching.
3)
Tools,
material control should be located within the maximum working area and as near
to the worker as possible.
4)
Tools,
materials should be arranged to permit the best sequence of motions.
5)
A
comfortable chair should be provided. It should be possible for the worker to
put both knees under the bench.
6)
Adequate
natural or artificial lighting should be provided.
7)
A
pleasing color scheme makes the work place attractive.
Design
of tools and equipment: -
1)
The
hand should be relieved of all work of holding the work place where this can be
done by jig, fixture or foot operated device.
2)
Two
or more tools should be combined wherever possible.
SAM/SAH
Standard
allocated minute.
Standard Worker
The
standard worker is that worker who has the consistency.
A
qualified worker is one who has acquired the skill, knowledge and other
attributes to carry out the work in
hand to satisfactory standard of quality, quantity and safety.
4th Day
What is Work measurement?
Work
measurement is the application of techniques design to establish the time for a
qualified worker to carry out a specified job at a defined level of
performance.
Objectives of work measurement:
1)
Planning: Work measurement data forms
a reliable basis for planning and loading men and machine so that management is
to able to utilize these resources to the best advantage.
2)
Control: Reliable figure of actual
use of resources are invaluable for the management for making sound decision on
how to increase productive efficiency.
3)
Incentive: It provides basis for a
fair and realistic incentive scheme.
4)
Budgeting: It provides information for
labor budgeting systems.
5)
Costing: It provides basis for
standard costing system.
6)
To
find out individual worker capacity
7)
To
find out line capacity.
8)
To
find out bottleneck area.
9)
To
find out effective time.
10)To establish the standard time (SAM/SMV/SAH).
11)To find out worker/line efficiency.
12)To know the worker/line productivity gap.
Uses of work measurement:
1)
To
compare the efficiency of alternative method, the method, which takes the least
time, will be the best method.
2)
To
balance the work of members of teams, as nearly as possible each member has a
task taking an equal time to perform.
3)
To
provide information that can enable to estimates the delivery date.
4)
To
set standards of machine manpower utilization and labor performance.
To
provide information for labor cost control and to enable standard cost to be
fixed and maintained.
What is time study?
Time study is a work measurement technique for
recording the time of performing a certain/specified conditions and for
analyzing the data so as to obtain time necessary for an operator to carry out
at a define rate of performance.
GSD
General
sewing data (G.S.D) is a technique for method analysis & setting of time
standards for sewn products industry.
GSD
is predetermined Motion time system & was devised by methods workshop
limited in 1978. It was developed to provide a consistent, accurate, and easy
to understand, easy to communicate, methods analysis & time standards
determination technique.
How does GSD work?
1.
Each
movement has a code.
2.
Each
code has corresponding time value that takes into account of the distance moved
& the degree of difficulty of the motions.
3.
By
using these codes we can record in detail an operation.
Capacity Study
To check how many an
operator can produce in 1 hour.
Procedure:
·
Time
& record a number of observations.
·
Calculate
the average observed time
·
Add
allowances
·
Calculate
the capacity per hour
·
Analyze
& interpret the result to the supervisor / in- charge.
Where we can apply time study?
1)The
job in question a new one, not previously carried out new product, component,
operations or set up activities.
2)
A
change in material or method of working has been made and new time standard is
required.
3)
A
complains has been received from a worker or workers representative about the
time standard of the operation.
4)
A
particular operation appears to be a bottleneck holding up sub-sequent
operation and possibly previous operations.
5)
Standard
times are required before an incentive scheme is introduced.
6)
A
piece of equipment appears to be idle for an excessive time or its output is
low and if there for becomes necessary to be investigated the method of it uses.
7)
The
job needs studying as a preliminary to make a method study or to compare the
efficiency of two methods.
The
cost of a particular job appears to be excessive as may be evidence by a Pareto
type analysis.
The equipment used for time study
1)
Stop
watch
2)
Clip
board
3)
Time
study format
4)
Pencil
5)
Eraser
6)
Calculator
5th Day
Bottleneck:
Which
are holding up production operations, or a lengthy operation, that consumes a great
deal of time.
A
bottleneck is the operation in any team that has the lowest capacity of
production.
** What is the meaning of bottleneck?
Bottlenecks
mean lost production lost profit.
What is the reason of bottleneck?
A
bottleneck may be raised in the line for the following reasons…
1> If the said operator has more
work content than other operators.
2> If the operator is unskilled
or semi skilled in respect to the operation.
3> If there happens quality
fault in the operation.
4> If two or various types
(color) of thread are used in the same machine.
5> If there is any problem in
machinery purpose.
How to find bottleneck?
Find
bottleneck in team using cycle’s checks / by continuous follow up in line.
How to solve bottlenecks?
Two
things are very essential to solve a bottleneck.
A> Gathering information
regarding the operation.
B> Complete analysis of the
operation.
Using the following steps can solve
bottleneck………………….
1> Selection the correct
operator/ operation.
2> Improve operator performance
(skill/speed)
3> Improve method
4> Reduce work content of
operation.
5> Additional machinery /
operator.
6> Old methods E.G before
automatic M/C were invented.
7> Ensure bottleneck is not
working on faulty production produced before the bottleneck.
Bottleneck=10pcs / hr=100/day
But two per hour go to
operation before bottleneck (for repair) & need again to pass through
bottleneck.
Bottleneck capacity= 10-2
Repairs (Not own)
= 8 / hr=80
/ day (10 hrs)
I.E. Further 20 jobs lost.
8> Find capacity elsewhere in
line factory.
9> Work lunch breaks / overtime
/ shifts I.E maximize sewing time.
10>
If
absolutely necessary Add Helper in addition E.C unpicking repairs, turning
through etc. maximize sewing time.
Line Balance
For
line balance we have to know some data some calculating information.
Those
are: -
1> How many operator
2> Operation
3> SMV
4> Performance %
5> Potential production / hr
6> Hours to achieve target
7> Capacity
8> Target
Others
are: -
Ø
Color
of sewing thread
Ø
Types
of machine
Ø
The
foot or attachment
Cycle check: cycle check is a work measurement
technique to measure the time taken the operators, when they are performing
their jobs by using a stopwatch.
Cycle check procedure:
1)
Select:
2)
Record:
3)
Check:
4)
Target
find out:
5)
Calculate
capacity
What is rating?
Rating
is the assessment of the worker rate of working relative to the observer’s
concept of the rate corresponding to standard pace.
Rating scale:
1)
60—80
2) 75—100
3) 100—135
4) 0—100(British standard, ILO
Certified)
Details
of British standard rating scale:
1)
0=
No activity.
2)
1—50=
Very slow, clumsy, operator appears to be half asleep, fumbling movement, weak
and no interest in the job.
3)
51—75=
Trying to get output but for their handling problem, less attentiveness they
cannot make sure the quality and output also.
4)
76—100=
very faster than other operators. They are working with their 100%
concentration and make the garment with satisfactory quality and quantity
level.
Factors affecting the rating:
The study person should be careful not to rate too
highly when:
1) The worker
is worried or looks hurried.
2)
The worker is obviously being over careful.
3)
The job seems to be difficult to the study
person.
4)
The study person is working very fast as when
recording a short element study.
The study person should be careful not to be rate
too low when:
1) The job looks easy.
2)
The worker is using smooth rhythmic movement.
3)
The worker does not pause to think when the
study person expects this.
4)
The worker is performing heavy manual work.
5)
The study person is tired.
Characteristics of work-study officer:
1.
Sincerity
2.
Enthusiasm
3.
Interest
in and sympathy with people
4.
Tactful
5.
Good
appearance
6.
Self
confidence
6th
Day
Some Important Formula
Observe
time = Total
cycle time/ No. Of cycle
Basic
time =
Observe time X rating
SAM = Basic time + (Basic time x
Allowance)
Rating= Observe rating x Observe
rating / Standard rating.
Sam= Standard allocated minute.
What is target?
Target is the amount of production, which should be
produced by an operator or a line that a management desires.
No. Of worker x w/hour x 60
Target= x Expected
efficiency.
S.M.V
Suppose;
Total operator------- 20
W/hour--------------- 08Hrs
SMV-------------------- 15.65
Expected eff.---------- 85%
20 x 08 x 60
So. Target =-------------------------- x 85%
15.65
= 520ps
= 65ps/Hr.
Allowance:
1)
Bundle handling basic minutes.
2)
Relaxation & contingency allowance.
Relaxation
allowance: It is an addition to the basic time intended to provide the
worker with the opportunity to recover from the physiological and physiological
effects of carrying out specified work under specified condition and to allow
attention well depend on the nature of the job.
Contingency allowance: A contingency allowance is
small allowance of time which may be included to standard time to meet
legitimate and expected items of working delays is the precise measurement of
which is going on.
7th Day
Efficiency
= Earned minutes / Available minutes x 100
Performance=
Earned minutes / Available minutes-Lost timex100
Available
minutes= No. Of SAM earners x working minutes
Earned minutes = Total production X SAM
Operation Break Down
Performance
This
is a figure, which we calculate after reducing the lost time from the available
minutes. This will give a clear idea about the exact lost time, which effected
for low efficiency. The above a few types of lost time, which can affect for a
sewing lines production. Lost time is also called as off-standard time &
Non-productive time.
Earned
minute
------------------------------------------
X 100
Available
minutes – Lost time
8th
Day
Skill
inventory.
CPM
=
TOTAL OVERHEAD COST FOR THE MONTH
NO OF SMV EARNERS X WORKING MINUTES X EFFICIENCY
NO OF SMV EARNERS X WORKING MINUTES X EFFICIENCY
Capacity
Booking
Capacity filling should be done in minutes. Which means the
marketing department will have to sell the minutes available of the company.
Working Minutes: 480minutes /day (For 8 hrs.)
No. Of Workers /Line: 25
Available Minutes /Line: 25x480= 12000mnts
No. Of Lines In The Factory: 20
Total Available Minutes /Day: 12000x20=240000mnts
No. Of Working Days/Month: 24
Available Minutes /Month: 240000x24=5760000
Average Factory Efficiency%: 65%
Actual Available minutes / Month: 5760000x65%=3744000
This 3744000mnts is the factory capacity.
So as an example if a buyer comes with a style of SAM 10,the
factory, which has the above capacity, will be able to do only 374400pcs.
Lost Time
CD
– Cutting Delay
CM-
Cutting Mistake
MB-
Machine Breakdown
MD-
Machine Delay
FBD-
Fabric Delay
FD-
Feeding Delay
AD-
Accessories Delay
PD
– Printing Delay
ED-
Embroidery Delay
PF-
Power Failure
CS-
Color Shading
RW-
Re-work
RF-
Re-feeding
SCD-
Style Changing Delay
9th
Day
Operation
Break down & Layout (Practical).
10th
Day
Revise
class & evaluation test.
The End
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