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Reference Book
Production and Operation Management, by S. Anil Kumar
and N. Suresh

 Work-study forms the basis for work system design.

 The purpose of work design is to identify the most effective means of
achieving necessary functions.
 This work-study aims at improving the existing and proposed ways of
doing work and establishing standard times for work performance.
 Work-study is encompassed by two techniques,
method study and
work measurement.

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 “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 costs.”
 “Work measurement is the application or techniques designed to
establish the time for a qualified worker to carry out a specified
job at a defined level or performance.”
 Method study is concerned with the reduction of the work
content and establishing the one best way of doing the job
whereas work measurement is concerned with investigation and
reduction of any ineffective time associated with the job and
establishing time standards for an operation carried out as per
the standard method.

 Productivity is the quantitative relation between what we

produce and we use as a resource to produce them, i.e.,
arithmetic ratio of amount produced (output) to the amount
of resources (input). Productivity can be expressed as:

 Productivity refers to the efficiency of the production

system.

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 Total tangible output =

Value of finished goods produced + Value of partial units
produced + Dividends from securities + Interest+ Other
income
 Total tangible input =
Value of (human + material + capital + energy + other
inputs) used.
 The word tangible here refers to measurable.

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Technology Based
1. Computer Aided Design (CAD), Computer Aided
Manufacturing (CAM), and
Computer Integrated Manufacturing Systems (CIMS):
2. Computer integrated manufacturing

EMPLOYEE BASED
1. Financial and non-financial incentives at individual and group level.
2. Employee promotion.
3. Job design, job enlargement, job enrichment and job rotation.
4. Worker participation in decision-making
5. Quality Circles (QC), Small Group Activities (SGA)
6. Personal development.

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MATERAL BASED
1. Material planning and control
2. Purchasing, logistics
3. Material storage and retrieval
4. Source selection and procurement of quality material
5. Waste elimination.

PROCESS BASED
1. Methods engineering and work simplification
2. Job design evaluation, job safety
3. Human factors engineering.

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PRODUCT BASED TASK BASED

1. Value analysis and value engineering 1. Management style
2. Product diversification 2. Communication in the organization
3. Standardization and simplification 3. Work culture
4. Reliability engineering 4. Motivation
5. Product mix and promotion. 5. Promotion group activity.

A company produces 160 kg of plastic molded parts of acceptable quality by consuming

200 kg of raw materials for a particular period. For the next period, the output is doubled
(320 kg) by consuming 420 kg of raw material and for a third period, the output is
increased to 400 kg by consuming 400 kg of raw material.

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The following information regarding the output produced and inputs consumed for a
particular time period for a particular company is given below:
Output – Rs. 10,000
Human input – Rs. 3,000
Material input – Rs. 2,000
Capital input – Rs. 3,000
Energy input – Rs. 1,000
Other misc. input – Rs. 500
The values are in terms of base year rupee value. Compute various productivity
indices.

Output – Rs. 10,000

Human input – Rs. 3,000
Material input – Rs. 2,000
Capital input – Rs. 3,000
Energy input – Rs. 1,000
Other misc. input – Rs. 500

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Work study is a generic term for those techniques, method study and work measurement which
are used in the examination of human work in all its contexts. And which lead systematically to
the investigation of all the factors which affect the efficiency and economy of the situation being
reviewed,in order to effect improvement.

• It enhances the production efficiency

(productivity) of the firm by elimination of waste
and unnecessary operations.
• It is a technique to identify non-value adding
operations by investigation of all the factors
affecting the job.
• It is the only accurate and
systematic procedure oriented technique to
establish time standards.
• It is going to contribute to
the profit as the savings will start immediately
and continue throughout the life of the product.

1. It helps to achieve the smooth production flow with minimum interruptions.

2. It helps to reduce the cost of the product by eliminating waste and unnecessary operations.
3. Better worker-management relations.
4. Meets the delivery commitment.
5. Reduction in rejections and scrap and higher utilization of resources of the organization.
6. Helps to achieve better working conditions.
7. Improves upon the existing process or methods and helps in standardization and
simplification.
8. Helps to establish the standard time for an operation or job which has got application in
manpower planning, production planning.

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According to British Standards Institution: “Method study is the systematic recording and
critical examination or existing and proposed ways or doing work as a means or developing
and applying easier and more effective methods and reducing cost.”

Method study is essentially concerned with finding better ways of doing things. It adds
value and increases the efficiency by eliminating unnecessary operations, avoidable
delays and other forms of waste.

Scopes of method study:

1. Manufacturing operations and their sequence.
2. Workmen.
3. Materials, tools and gauges.
4. Layout of physical facilities and work station
design.
5. Movement of men and material handling.
6. Work environment.

Select
• Work which can be studied with economic advantages

Record
• All facts about the job/work

Examine
• The facts critically seek alternatives, simplify, eliminate combine or change.

Develop
• A record of an improved method and selecting the best method.

Evaluate
• Evaluate different alternatives comparing with cost effectiveness.

Define
• Method, Procedure, layout, materials etc.

Install
• The improved method, plan arrange and implement.

Maintain
• Verify at regular intervals

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The job should be selected for the method study based upon the following
considerations:
1. Economic aspect
2. Technical aspect, and
3. Human aspect.

Economic Aspects Technical Aspects

(a) Bottleneck operations which are holding up The method study man should be careful
other production operations. enough to select a job in which he has the
(b) Operations involving excessive labor. technical knowledge and expertise.
(c) Operations producing lot of scrap or A person selecting a job in his area of
defectives. expertise is going to do full justice.
(d) Operations having poor utilization of
resources.
(e) Backtracking of materials and excessive
movement of materials.

The job should be selected for the method study based upon the following
considerations:
1. Economic aspect
2. Technical aspect, and
3. Human aspect.

Human Considerations

These are some of the situations where human aspect should be

given due importance:

1. Workers complaining about unnecessary and tiring work.

2. More frequency of accidents.
3. Inconsistent earning.

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It can be broadly divided into (A) Macro motion charts and (B) Micro motion charts.

Macro motion study is one which can be measured through ‘stop watch’ and micro
motion study is one which cannot be measured through stop watch.

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Operation Process Chart

The operation process chart shows the chronological sequence of all

operations, inspections, time allowances, and materials used in a
manufacturing or business process, from the arrival of raw material to the
packaging of the finished product.

The chart depicts the entrance of all components and subassemblies to

the main assembly.

Two symbols are used in constructing the operation process Chart : an

operation and an inspection.

Flow Process Chart

Flow process chart gives the sequence of flow of work of a product or any
part of it through the work center or the department recording the events
using appropriate symbols.
It is the amplification of the operation process chart in which operations;
inspection, storage, delay and transportation are represented.

Process charts are of three types:

(a) Material type—Which shows the events that occur to the materials.
(b) Man type—Activities performed by the man.
(c) Equipment type—How equipment is used.

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 FLOW DIAGRAM
Flow diagram is a drawing, of the working area, showing the location of
the various activities identified by their numbered symbols and are
associated with particular flow process chart either man type or machine
type.
Following are the procedures to make the flow diagram:

1. The layout of the workplace is drawn to scale.

2. Relative positions of the machine tools, work benches, storage, and
inspection benches are marked on the scale.
3. Path followed by the subject under study is tracked by drawing lines.
4. Each movement is serially numbered and indicated by arrow for
direction.
5. Different colours are used to denote different types of movements.

 FLOW DIAGRAM

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 STRING DIAGRAM

The string diagram is a scale layout drawing on which, length of a string

is used to record the extent as well as the pattern of movement of a
worker working within a limited area during a certain period of time.
The primary function of a string diagram is to produce a record of an
existing set of conditions so that the job of seeing what is actually taking
place is made as simple as possible.

The main advantages of string diagram compared to flow diagram is that

respective movements between work stations which are difficult to be
traced on the flow diagram can be conveniently shown on string
diagram.

 STRING DIAGRAM

Following are the procedures to draw string

diagram:
1. A layout of the work place of factory is
drawn to scale on the soft board.
2. Pins are fixed into boards to mark the
locations of work stations, pins are also
driven at the turning points of the routes.
3. A measured length of the thread is taken
to trace the movements (path).
4. The distance covered by the object is
obtained by measuring the remaining part
of the thread and subtracting it from
original length.

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Operation O
Ο OPERATION
An operation occurs when an object is intentionally
INSPECTION changed in one or more of its characteristics (physical
or chemical). This indicates the main steps in a process,
method or procedure.
→ TRANSPORTATION
Examples of operation are:
D DELAY Turning, drilling, milling, etc.
A chemical reaction.
∇ STORAGE Welding, brazing and riveting.
Lifting, loading, unloading.

Inspection
Ο OPERATION
An inspection occurs when an object is examined
INSPECTION and compared with standard for quality and
quantity.
→ TRANSPORTATION
The inspection examples are:
D DELAY Visual observations for finish.
Count of quantity of incoming material.
Checking the dimensions.
∇ STORAGE

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Transportation →
Ο OPERATION
A transport indicates the movement of workers,
INSPECTION materials or equipment from one place to another.

→ TRANSPORTATION Example:
Movement of materials from one work station
D DELAY to another.
Workers travelling to bring tools.
∇ STORAGE

Delay D: Delay (Temporary Storage)

Ο OPERATION
A delay occurs when the immediate performance
INSPECTION of the next planned thing does not take place.

→ TRANSPORTATION Example:
Work waiting between consecutive operations.
D DELAY Workers waiting at tool cribs.

Operators waiting for instructions from

∇ STORAGE supervisor.

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Storage ∇
Ο OPERATION
Storage occurs when the object is kept in an
INSPECTION authorized custody and is protected against
unauthorized removal.
→ TRANSPORTATION
For example, materials kept in stores to be
D DELAY distributed to various work.

∇ STORAGE

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Micro-motion study provides a technique for recording and timing an activity.

It is a set of techniques intended to divide the human activities in a groups of movements

or micro-motions and the study of such movements helps to find for an operator one best
pattern of movements that consumes less time and requires less effort to accomplish the
task.

The “Therbligs” are micro-motion study involves the following steps:

1. Filming the operation to be studied.
2. Analysis of the data from the film.

SIMO Chart
Simultaneous motion cycle chart (SIMO chart) is a recording technique for micro-motion
study. A SIMO chart is a chart based on the film analysis, used to record simultaneously on
a common time scale the Therbligs or a group of Therbligs performed by different parts of
the body of one or more operators.

The objectives of work measurement are to provide a sound basis for:

1. Comparing alternative methods.
2. Assessing the correct initial manning (manpower requirement planning).
3. Planning and control.
4. Realistic costing.
5. Financial incentive schemes.
6. Delivery date of goods.
7. Cost reduction and cost control.
8. Identifying substandard workers.
9. Training new employees.

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According to British Standard Institute time study has been defined as

“The application of techniques designed to establish the time for a qualified
worker to carry out a specified job at a defined level of performance.”
Steps in Making Time Study

1. Select the work to be studied.

2. Obtain and record all the information available about the job, the operator
and the working conditions likely to affect the time study work.
3. Breakdown the operation into elements..
4. Measure the time by means of a stop watch taken by the operator to
perform each element of the operation.
5. At the same time, assess the operators effective speed of work relative to
the observer’s concept of ‘normal’ speed. This is called performance rating.

Steps in Making Time Study

6. Adjust the observed time by rating factor to obtain normal time for each
element

7. Add the suitable allowances to compensate for fatigue, personal needs,

contingencies. etc. to give standard time for each element.
8. Compute allowed time for the entire job by adding elemental standard
times .
9. Make a detailed job description describing the method for which the
standard time is established.
10. Test and review standards wherever necessary.

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The normal time for an operation does not contain any allowances for the
worker. It is impossible to work throughout the day even though the most
practicable, effective method has been developed.

Even under the best working method situation, the job will still demand
the expenditure of human effort and some allowance must therefore be
made for recovery from fatigue and for relaxation.

Allowances must also be made to enable the worker to attend to his

personal needs.
The allowances are categorized as:
(1) Relaxation allowance,
(2) Interference allowance, and
(3)Contingency allowance.

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Assuming that the total observed time for an operation of assembling an electric switch is 1.00
min. If the rating is 120%, find normal time. If an allowance of 10% is allowed for the operation,
determine the standard time.

An operator manufactures 50 jobs in 6 hours and 30 minutes.

If this time includes the time for setting his machine. Calculate the operator’s efficiency.
Standard time allowed for the job was:
Setting time = 35 min
Production time per piece = 8 min

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