Work-Measurement KEC

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Work Measurement

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INTRODUCTION

 Work measurement is the application of techniques designed


to establish the time for a qualified worker to carry out
specified jobs at a defined level of performance.

 Work measurement (WM) is concerned with investigating,


reducing and eliminating ineffective time, whatever may be
the cause.

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INTRODUCTION

Two critical issues in work study:

1. Method study should precede the work measurement, always.

2. Elimination of management controllable ineffective time should


precede the elimination of the ineffective time within the control
of the workers.

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USES OF WM
 To compare the efficiency of alternative methods. Other
conditions being equal, the method which takes the least time will
be the best method.

 To balance the work of members of teams, in association with the


multiple activity charts, so that, as far as possible, each member
has tasks taking an equal time.

 To determine, in association with man and machine multiple


activity charts, the number of machines an worker can run.

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TOOLS USED IN TIME STUDY

 Stop watch
 Time study board

 Time study chart

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TECHNIQUES FOR WM

 Time study
 Work sampling
 Synthesis from standard data
 Pre-determined motion time system

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TIME STUDY
A WM technique for:
1. Recording the times and rates of working for the
elements of a specified job carried out under
specified conditions,

2. Analyzing the data so as to obtain the time


necessary for carrying out the job at a defined level
of performance.

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STEPS IN TIME STUDY

• The job to be timed


select

Obtain • Method, operator, job, working conditions


&
record

• Breaking into elements


define

Measu • Time duration for each element


re

• Observed time into normal time


Extend

Deter • Allowances
mine

compu • Standard time


te

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SELECTING A JOB FOR TIME STUDY
 New one not previously carried out.
 A change in material or method of working.
 A complaint has been received about the time standard for an
operation.
 A particular bottleneck operation.
 Prior to the introduction of an incentive scheme.
 Investigate the utilization of a piece of plant, the output is low,
or which appears to be idle for an excessive time.
 To compare the efficiency of two proposed methods.
 The costs of a particular job appears to be excessive.
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QUALIFIED WORKER

 One who is accepted as having the necessary physical attributes,


who possesses the required intelligence, education, and has
acquired the necessary skill and knowledge to carry out the work
in hand to satisfactory standard of safety, quantity and quality.

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OBTAIN AND RECORD

 Selection of operator
 Identification details i.e part number, name,
machine, feed, material spec, operator details
 Working conditions

 Work positions

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BREAKING THE JOB INTO ELEMENTS

 An element is an distinct part of a specified job selected for


convenience of observation, measurement and analysis.

 A work cycle is the sequence of elements which are required to


perform a job or yield a unit of production. The sequence may
sometimes include occasional elements.

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REASONS FOR BREAKDOWN OF JOB
For each job, a detailed breakdown of the complete job into
elements is necessary. Because….
 To separate productive work (or effective time) from
unproductive activity (or ineffective time).
 To enable different types of elements to be identified and
distinguished, so that each may be accorded the treatment
appropriate.
 To enable elements involving high fatigue to be isolated and
to make the allocation of fatigue allowances more accurate.

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TYPES OF ELEMENTS
 A repetitive element is an element which occurs in every work
cycle of the job.
 An occasional element does not occur in each work cycle of the
job, but which may occur at regular or irregular intervals. e.g.
machine setting.
 For a constant element, the basic time remains constant
whenever it is performed. e.g. switch the machine on.
 A variable element is an element for which the basic time varies
in relation to some characteristics of the product, equipment or
process, e.g. dimensions, weight, quality etc. e.g. push trolley of
parts to next shop.

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TYPES OF ELEMENTS
 A manual element is an element performed by a worker.
 A machine element is automatically performed by a power-driven
machine (or process).
 A governing element occupies a longer time than any of the other
elements which are being performed concurrently. e.g. boil kettle
of water, while setting out teapot and cups.
 A foreign element is observed during a study which, after analysis,
is not found to be necessary part of the job. e.g. degreasing a part
that has still to be machined further.

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RECORDING TIME FOR ACTIVITIES
Cumulative timing
 The watch runs continuously throughout the study.

 At the end of each element the watch reading is recorded.

 The individual element times are obtained by subsequent


subtractions.
 The purpose of this procedure is to ensure that all the time during
which the job is observed is recorded in the study.
 Typically, most work-study persons attain fair degree of accuracy
quickly when using the cumulative method.

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RECORDING TIME FOR ACTIVITIES
Flyback time

 The hands of the stopwatch is returned to zero at the end of each


element and are allowed to start immediately, the time for each
element being obtained directly.

 In a comparative study of two methods carried out the Purdue


University, the average error in reading the watch using the
cumulative method was +0.000097 min per reading and using the
flyback method was -0.00082 min per reading.

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TIME STUDY: RATING

 Rating is the assessment of the worker’s rate of working relative to


the observer’s concept of the rate corresponding to the standard
pace.

 The standard level is the average rate at which qualified workers


will naturally work at a job, when using the correct method and
when motivated to apply themselves to their work. This rate of
working is called standard rating.

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FACTORS AFFECTING RATE OF WORKING

Factors outside the control of workers include:

 Variation in the quality or other characteristics of the material used,


although they be within the prescribed tolerance limit.

 Changes in the operating efficiency of tools or equipment within their


normal life.

 Minor and unavoidable changes in methods or conditions of operations.

 Variation in the mental attention for the performance of elements.

 Changes in the climatic and other conditions.

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RATING FACTOR

 This constant is known as the basic time:


Rating
Observed time x  Basic Time
100

 So, depending on the rating assigned for the operator, the


basic time can either be less than or greater than the
observed time.

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WORK CONTENT

 The work content of a job or operation is defined as: basic time+


relaxation allowance+ any allowance for additional work (e.g. the
part of relaxation allowance that is work related).

 Standard time is the total time in which a job should be completed


at standard performance – i.e. work content, contingency
allowance for delay, unoccupied time and interference allowance.

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ALLOWANCES
 A contingency allowance is a small allowance of time which may
be included in a standard time to meet legitimate and expected
items of work or delays, precise measurement of which is
uneconomical because of their infrequent or irregular occurrence.
 Contingency allowance could be no more than 5%, and should
only be given where the contingencies cannot be eliminated and
are justified.
 Tool breakage, power failures, obtaining tools and gauges from
stores.

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 Relaxation allowance is an addition to the basic time intended to
provide the worker with the opportunity to recover from the
physiological and psychological effects of carrying out specified
 The amount of the allowance will depend on the nature of the job.
 Typical values of relaxation allowance are 5% for men and 7%
for women.
 Meeting personal needs.

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OTHER ALLOWANCES
 Start-up / shut-down allowance
 Cleaning allowance
 Tooling allowance
 Set-up / change-over allowance
 Reject / excess production allowance
 Learning / training allowance
 Policy allowance is an increment, other than the bonus increment,
applied to standard time to provide a satisfactory level of earning
for certain level of performances under exceptional conditions.

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STANDARD TIME
 Now, we can add all the constituents to arrive at the standard time
for a job.
Standard time = observed time * rating factor + relaxation allowance
+ work related contingency allowance + delay related contingency
allowance.

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REST ALLOWANCES
1. Constant allowance
(A) Personal allowance ……………... 5
(B) Basic fatigue allowance ………… 4
2. Variable allowances:
(A) Standing allowance ……………… 2
(B) Abnormal position
(i) Awkward (bending) ………… 2
(ii) Very awkward (lying,
stretching) …………………… 7
Figure S10.1
REST ALLOWANCES
(C) Use of force or muscular energy in
lifting, pulling, pushing
Weight lifted (pounds)
20 …………………………………… 3
40……………………………………. 9
60……………………………………. 17
(D) Bad light:
(i) Well below recommended…. 2
(ii) Quite inadequate……………. 5
Figure S10.1
REST ALLOWANCES

(E) Atmospheric conditions


(heat and humidity) …………… 0-10
(F) Close attention:
(i) Fine or exacting……………….. 2
(ii) Very fine or very exacting…… 5
(G) Noise level:
(i) Intermittent—loud…………….. 2
(ii) Intermittent—very loud
or high-pitched………………... 5
Figure S10.1
REST ALLOWANCES

(H) Mental strain:


(i) Complex or wide span
of attention.…………………….. 4
(ii) Very complex………………….. 8
(I) Tediousness:
(i) Tedious…………..……………… 2
(ii) Very tedious.…………………… 5

Figure S10.1
TIME STUDY EXAMPLE
Allowance factor = 15%

Cycle Observed (in minutes)


Performance
Job Element 1 2 3 4 5 Rating
(A) Compose and type letter 8 10 9 21* 11 120%
(B) Type envelope address 2 3 2 1 3 105%
(C) Stuff, stamp, seal, and 2 1 5* 2 1 110%
sort envelopes

1. Delete unusual or nonrecurring observations (marked with *)


2. Compute average times for each element
Average time for A = (8 + 10 + 9 + 11)/4 = 9.5 minutes
Average time for B = (2 + 3 + 2 + 1 + 3)/5 = 2.2 minutes
Average time for C = (2 + 1 + 2 + 1)/4 = 1.5 minutes
TIME STUDY EXAMPLE
3. Compute the normal time for each element

Normal time = (Average observed time) x (Rating)

Normal time for A = (9.5)(1.2) = 11.4 minutes


Normal time for B = (2.2)(1.05) = 2.31 minutes
Normal time for C = (1.5)(1.10) = 1.65 minutes

4. Add the normal times to find the total normal time

Total normal time = 11.40 + 2.31 + 1.65 = 15.36 minutes


TIME STUDY EXAMPLE
5. Compute the standard time for the job

Standard time = Total normal time * (1 + Allowance factor)


= 15.36 * (1+.15) = 17.66 minutes
DETERMINE SAMPLE SIZE
2
zs
Required sample size = n =
hx

where h = accuracy level desired in percent of the job element


expressed as a decimal
z = number of standard deviations required for the desired
level of confidence
s = standard deviation of the initial sample
x = mean of the initial sample
n = required sample size

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