Principles of Motion and Time Study in Work Design
Productivity and Quality
Management
Lecture 15
Motion and Time Study
(MTS)
Summary Last Lecture
Work
Meas.mnt
Methods
Design
Methodology
Outline of MTS
•
Develop System
–
Design work methods
(sequence of operations and
procedures) that make up the
preferred solution
–
Find better methods for work
•
Standardize
–
Form written standards for
operations
•
Time Standards
–
Determine a standard time for
each operation
•
Training
–
Train the operators
Develop System
Standardize
Time Standards
Training
Defining Work Systems
Work
•
Is our primary means of livelihood
•
Serves an important economic function in the
global world of commerce
•
Creates opportunities for social interactions
and friendships
•
Provides the products and services that
sustain and improve our standard of living
Defining Work Systems
•
Work consists of tasks
–
Tasks consist of work
elements
•
Work elements consist of basic
motion elements
Motion Study
Principles of Motion Economy
•
Developed over many years of practical experience in
work design
•
Guidelines to help determine
–
Work method
–
Workplace layout
–
Tools, and equipment
•
Objective: to maximize efficiency and minimize
worker fatigue
Work Methods Design
To select preferred work method:
1.
Eliminate all unnecessary work
2.
Combine operations or elements
3.
Change the sequence of operations
4.
Simplify the necessary operations
THIS LECTURE
TIME STUDY
Time Stud
y
“Time study is the one element in scientific
management beyond all others making possible
the transfer of skill from management to men…..”
–
Frederick W. Taylor
•
Time Study measures how long it takes for an
average worker to complete a task at a normal
pace
Time Study and Work Measurement
Time Is Important
•
Most workers are paid for their time on the job
•
The labor content (cost of labor time) is often a
major factor in the total cost of a product or
service
•
For any organization, it is important to know how
much time will be required to accomplish a given
amount of work
Time Study and Work Measurement
•
Work measurement – evaluation of a task in
terms of the time that should be allowed by
an average worker to perform the task
•
Time study – all the ways in which time is
analyzed in work situations
•
Standard time – amount of time that should
be allowed for an average worker to process
one work unit using the standard method and
working at normal pace
Time Study and Work Measurement
Standard times
•
define a “fair day’s work”
•
provide a means to convert workload into staffing
and equipment needs
•
provide a basis for wage incentives and evaluation of
worker performance
•
provide time data for:
–
Production planning and scheduling
–
Cost estimating
–
Material requirements planning
Task Hierarchy & Work Measurement
Time Study and Work
Measurement
Prerequisites for Valid Time Standards
: Factors that must be standardized before
a time standard can be set
Time Study and Work Measurement
Time Study and Work Measurement
Normal Performance
•
A pace of working that can be maintained by a
properly trained
average worker
throughout an
entire work shift without deleterious short-
term or long-term effects on the worker’s
health or physical well-being
–
Normal performance = 100% performance
–
Common benchmark of normal performance:
•
Walking at 3 mi/hr
Time Study and Work Measurement
Performance Rating
•
Analyst judges the performance or pace of the
worker relative to the definition of standard
performance used by the organization
–
Standard performance
P
w
= 100%
•
Slower pace than standard
P
w
< 100%
•
Faster pace than standard
P
w
> 100%
–
Normal time
T
n
=
T
obs
(
P
w
)
Time Study and Work Measurement
Normal Time
•
The time to complete a task when working at
normal performance
T
n
=
T
obs
(
P
w
)
where
T
obs
=
observed
time,
T
n
= normal time,
and
P
w
= worker performance or pace
Time Study and Work Measurement
Example: Normal Performance
•
Given: A man walks in the early morning for
health and fitness. His usual route is 1.85 miles.
A typical time is 30 min. The benchmark of
normal performance = 3 mi/hr.
•
Determine: (a) how long the route would take at
normal performance and (b) the man’s
performance when he completes the route in 30
min.
Time Study and Work Measurement
(a) At 3 mi/hr, time = 1.85 mi / 3 mi/hr
= 0.6167 hr = 37 min
(b) Rearranging equation,
P
w
=
T
n
/
T
c
P
w
= 37 min / 30 min = 1.233 = 123.3 %
Reasons for Lost Time at Work
Work-related interruptions
•
Machine breakdowns
•
Waiting for materials or parts
•
Receiving instructions from
foreman
•
Talking to co-workers about
work-related matters
•
Rest breaks for fatigue
•
Cleaning up at end of shift
Non-work-related interruptions
•
Personal needs (e.g., restroom
breaks)
•
Talking to co-workers about
matters unrelated to work
•
Lunch break
•
Smoke break
•
Beverage break
•
Personal telephone call
Time Study and Work
Measurement
Time Study and Work Measurement
How to Allow
for Lost Time
•
Two approaches used by companies:
1.
Scheduled rest breaks during the shift
•
Typical - one 15-minute break in mid-morning and
another in mid-afternoon
2.
A PFD (Personal Fatigue Delay) allowance is
added to the normal time
This allows the worker to take a break on his/her own
time
Time Study and Work Measurement
PFD Allowance
•
Personal time
–
Rest room breaks, phone calls, water fountain stops,
cigarette breaks (5% typical)
•
Fatigue
–
Rest allowance to overcome fatigue due to work-related
stresses and conditions (5% or more)
•
Delays
–
Machine breakdowns, foreman instructions (5% typical)
Time Study and Work Measurement
Allowances in Time Standards
•
Normal time is adjusted by an allowance
factor
A
pfd
to obtain the standard time
•
Purpose of allowance factor is to compensate
for lost time due to work interruptions and
other reasons
Time Study and Work Measurement
Standard Time
•
Defined as the normal time but with an allowance
added in to account for losses due to personal time,
fatigue, and delays
T
std
=
T
n
(1 +
A
pfd
)
where
T
std
= standard time,
T
n
= normal time, and
A
pfd
= PFD allowance factor
where pfd = personal time, fatigue, and delays
•
Also called the
allowed time
Time Study and Work Measurement
Standard Performance
•
Same as normal performance, but
acknowledges that periodic rest breaks must
be taken by the worker
–
Periodic rest breaks are allowed during the work
shift
–
Other interruptions and delays also occur during
the shift
Time Study and Work Measurement
Standard Method
•
Must include all of the details on how the task is
performed, including:
–
Procedure - hand and body motions
–
Tools
–
Equipment
–
Workplace layout
–
Irregular work
–
Working conditions
–
Setup
Time Study and Work Measurement
P
w
rating
T
c
cycle
time
T
n
normal
time
A
pfd
allowances
T
std
standard
time
Time Study and Work Measurement
Irregular Work Elements
•
Elements that are performed with a frequency
of less than once per cycle
•
Examples:
–
Changing a tool
–
Exchanging tote pans of parts
•
Irregular elements are prorated into the
regular cycle according to their frequency
Time Study and Work Measurement
Example: Determining Standard Time
•
Given: The normal time to perform the regular work
cycle is 3.23 min. In addition, an irregular work
element with a normal time = 1.25 min is performed
every 5 cycles. The PFD allowance factor is 15%.
•
Determine (a) the standard time and (b) the number
of work units produced during an 8-hr shift if the
worker's pace is consistent with standard
performance.
Time Study and Work Measurement
(a)
Normal time
T
n
= 3.23 + 1.25/5
= 3.48 min
Standard time
T
std
= 3.48 (1 + 0.15)
= 4.00 min
(b) Number of work units produced during an 8-
hr shift
Q
std
= 8.0(60)/4.00 = 120 work units
Direct Time Study
•
Direct and continuous observation of a task using a
stopwatch or other timekeeping device to record the
time taken to accomplish the task
•
While observing and recording the time, an appraisal
of the worker’s performance level is made to obtain
the normal time for the task
•
The data are then used to compute a standard time
for the task
Direct Time Study
Direct Time Study Procedure
1.
Define and document the standard method
2.
Divide the task into work elements
3.
Time the work elements to obtain the observed time
T
obs
4.
Evaluate worker’s pace relative to standard performance to
obtain normal time
T
n
–
Called performance rating (
PR
)
T
n
=
T
obs
(
PR
)
5.
Apply allowance factor to compute standard time
T
std
=
T
n
(1 +
A
pfd
)
Direct Time Study
Document the Standard Method
•
Determine the “one best method”
–
Seek worker’s advice if possible
•
Documentation should include:
–
All of the steps in the method
–
Special tools, gauges, equipment and equipment settings (e.g., feeds
and speeds) if applicable
–
Irregular elements and their frequency
•
Once the standard method is defined, it should not be
possible for the operator to make further improvements
Direct time study form
Direct Time
Study
Direct Time Study
Example
•
A direct time study was taken on a manual work element
using the snapback method. The regular cycle consisted of
three elements, a, b, and c. Element d is an irregular element
performed every five cycles.
Work element
a
b
c
d
Observed time (min) 0.56
0.25
0.50
1.10
Performance rating 100%
80%
110%
100%
•
Determine (a) normal time and (b) standard time for the cycle
Direct Time Study
(a) Normal time:
T
n
= 0.56(1.00) + 0.25(0.80) + 0.50(1.0)
+ 1.10(1.0)/5 = 1.53 min
(b) Standard time:
T
std
= 1.53(1 + 0.15) = 1.76 min
Work Sampling
Statistical technique for determining the proportions
of time spent by subjects in various defined
categories of activity
•
Subjects = workers, machines
•
Categories of activity = setting up a machine,
producing parts, idle, etc.
•
For statistical accuracy
–
Observations must be taken at random times
–
Period of the study must be representative of the types of
activities performed by the subjects
Work Sampling
When is Work Sampling Appropriate?
•
Sufficient time is available to perform the study
–
Several weeks usually required for a work sampling study
•
Multiple subjects
–
Work sampling suited to studies involving more than one
subject
•
Long cycle times for the jobs covered by the study
•
Nonrepetitive work cycles
–
Jobs consist of various tasks rather than a single repetitive
task
Work Sampling
Example: How Work Sampling Works
•
A total of 500 observations taken at random times during a
one-week period (40 hours) on 10 machines with results
shown below.
Category
No. of observations
(1) Being set up
75
(2) Running production
300
(3) Machine idle
125
500
•
How many hours per week did an average machine spend in
each category?
Work Sampling
•
Proportions of time determined as number of
observations in each category divided by 500
•
Time in each category determined by multiplying
proportion by total hours (40 hr)
Category
Proportion
Hrs per category
(1) Being set up
75/500 = 0.15
0.15 x 40
= 6
(2) Running production
300/500 = 0.60
0.60 x 40
= 24
(3) Machine idle
125/500 = 0.25 0.25 x 40 = 10
Work Sampling
Work Sampling Applications
•
Machine utilization - how much time is spent by
machines in various categories of activity
–
Previous example
•
Worker utilization - how workers spend their time
•
Allowances for time standards - assessment of delay
components in PFD allowance factor
•
Average unit time - determining the average time on
each work unit
•
Time standards - limited statistical accuracy when
standards set by work sampling
Work Sampling
Observation
Form
Work Sampling
•
Manufacturing
•
Office
•
Banks
•
Department Stores
•
Hospitals
•
Are production
costs too high (is there a
problem)?
•
Why is there a problem?
•
How can it be solved?
•
Which alternative is better?
•
Choose the best alternative
%5
Production
İncrease
Conclusion
•
Motion and time study helps management
determine how much is produced by workers in a
specific period of time, therefore making it easier
to predict work schedules and output.
•
Motion and Time Study is a scientific method
designed by two different people for the same
purpose, to increase productivity and reduce unit
cost.
•
The two methods evaluate work and try to find
ways to improve processes.
References
•
Groover
,
Mikell P
.
,
Work Systems: The
Methods, Measurement & Management of
Work
,
2007
,
Prentice Hall
•
Barnes,
Ralph
M.
,
Motion and Time Study:
Design and
Measurement of Work
,
1990, John
Wiley & Sons Inc.
Improving Productivity
Motion and Time Study are essential aspects of work design, focusing on maximizing efficiency, minimizing worker fatigue, and improving productivity. These studies involve developing systems, standardizing work methods, determining time standards, and training operators. Work is defined as a livelihood source, serving economic functions, fostering social interactions, and enhancing living standards. Motion Study principles aim to optimize work methods and workplace layouts. Work Methods Design involves eliminating unnecessary work, combining operations, changing sequences, and simplifying tasks for improved efficiency.
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Presentation Transcript
Productivity and Quality Management Lecture 15
Motion and Time Study (MTS) Summary Last Lecture
Methodology Outline of MTS Develop System Design (sequence of operations and procedures) that make up the preferred solution Find better methods for work Standardize Form written standards for operations Time Standards Determine a standard time for each operation Training Train the operators work methods Methods Design Develop System Standardize Work Meas.mnt Time Standards Training
Defining Work Systems Work Is our primary means of livelihood Serves an important economic function in the global world of commerce Creates opportunities for social interactions and friendships Provides the products and services that sustain and improve our standard of living
Defining Work Systems Work consists of tasks Tasks elements Work elements consist of basic motion elements consist of work
Motion Study Principles of Motion Economy Developed over many years of practical experience in work design Guidelines to help determine Work method Workplace layout Tools, and equipment Objective: to maximize efficiency and minimize worker fatigue
Work Methods Design To select preferred work method: 1. Eliminate all unnecessary work 2. Combine operations or elements 3. Change the sequence of operations 4. Simplify the necessary operations
THIS LECTURE TIME STUDY
Time Study Time study is the one element in scientific management beyond all others making possible the transfer of skill from management to men .. Frederick W. Taylor
Time Study measures how long it takes for an average worker to complete a task at a normal pace
Develop System Standardize Work Meas.mnt Time Standards Training Time Study and Work Measurement Time Is Important Most workers are paid for their time on the job The labor content (cost of labor time) is often a major factor in the total cost of a product or service For any organization, it is important to know how much time will be required to accomplish a given amount of work
Time Study and Work Measurement Work measurement evaluation of a task in terms of the time that should be allowed by an average worker to perform the task Time study all the ways in which time is analyzed in work situations Standard time amount of time that should be allowed for an average worker to process one work unit using the standard method and working at normal pace
Time Study and Work Measurement Standard times define a fairday swork provide a means to convert workload into staffing and equipment needs provide a basis for wage incentives and evaluation of worker performance provide time data for: Production planning and scheduling Cost estimating Material requirements planning
Time Study and Work Measurement Task Hierarchy & Work Measurement
Time Study and Work Measurement Prerequisites for Valid Time Standards: Factors that must be standardized before a time standard can be set
Time Study and Work Measurement Normal Performance A pace of working that can be maintained by a properly trained average worker throughout an entire work shift without deleterious short- term or long-term effects on the worker s health or physical well-being Normal performance = 100% performance Common benchmark of normal performance: Walking at 3 mi/hr
Time Study and Work Measurement Performance Rating Analyst judges the performance or pace of the worker relative to the definition of standard performance used by the organization Standard performance Pw = 100% Slower pace than standard Pw < 100% Faster pace than standard Pw > 100% Normal time Tn = Tobs(Pw )
Time Study and Work Measurement Normal Time The time to complete a task when working at normal performance Tn = Tobs(Pw ) where Tobs = observed time, Tn = normal time, and Pw = worker performance or pace
Time Study and Work Measurement Example: Normal Performance Given: A man walks in the early morning for health and fitness. His usual route is 1.85 miles. A typical time is 30 min. The benchmark of normal performance = 3 mi/hr. Determine: (a) how long the route would take at normal performance and (b) the man s performance when he completes the route in 30 min.
Time Study and Work Measurement (a) At 3 mi/hr, time = 1.85 mi / 3 mi/hr = 0.6167 hr = 37 min (b) Rearranging equation, Pw = Tn / Tc Pw = 37 min / 30 min = 1.233 = 123.3 %
Time Study and Work Measurement Reasons for Lost Time at Work Work-related interruptions Non-work-related interruptions Machine breakdowns Waiting for materials or parts Receiving instructions from foreman Talking to co-workers about work-related matters Rest breaks for fatigue Cleaning up at end of shift Personal needs (e.g., restroom breaks) Talking to co-workers about matters unrelated to work Lunch break Smoke break Beverage break Personal telephone call
Time Study and Work Measurement How to Allowfor Lost Time Two approaches used by companies: 1. Scheduled rest breaks during the shift Typical - one 15-minute break in mid-morning and another in mid-afternoon 2. A PFD (Personal Fatigue Delay) allowance is added to the normal time This allows the worker to take a break on his/her own time
Time Study and Work Measurement PFD Allowance Personal time Rest room breaks, phone calls, water fountain stops, cigarette breaks (5% typical) Fatigue Rest allowance to overcome fatigue due to work-related stresses and conditions (5% or more) Delays Machine breakdowns, foreman instructions (5% typical)
Time Study and Work Measurement Allowances in Time Standards Normal time is adjusted by an allowance factor Apfd to obtain the standard time Purpose of allowance factor is to compensate for lost time due to work interruptions and other reasons
Time Study and Work Measurement Standard Time Defined as the normal time but with an allowance added in to account for losses due to personal time, fatigue, and delays Tstd = Tn (1 + Apfd) where Tstd = standard time, Tn = normal time, and Apfd = PFD allowance factor where pfd = personal time, fatigue, and delays Also called the allowed time
Time Study and Work Measurement Standard Performance Same as acknowledges that periodic rest breaks must be taken by the worker Periodic rest breaks are allowed during the work shift Other interruptions and delays also occur during the shift normal performance, but
Time Study and Work Measurement Standard Method Must include all of the details on how the task is performed, including: Procedure - hand and body motions Tools Equipment Workplace layout Irregular work Working conditions Setup
Time Study and Work Measurement Tc Tn Tstd Pw rating Apfd allowances cycle time normal time standard time
Time Study and Work Measurement Irregular Work Elements Elements that are performed with a frequency of less than once per cycle Examples: Changing a tool Exchanging tote pans of parts Irregular elements are prorated into the regular cycle according to their frequency
Time Study and Work Measurement Example: Determining Standard Time Given: The normal time to perform the regular work cycle is 3.23 min. In addition, an irregular work element with a normal time = 1.25 min is performed every 5 cycles. The PFD allowance factor is 15%. Determine (a) the standard time and (b) the number of work units produced during an 8-hr shift if the worker's pace is consistent performance. with standard
Time Study and Work Measurement (a) Normal time Tn = 3.23 + 1.25/5 = 3.48 min Standard time Tstd = 3.48 (1 + 0.15) (b) Number of work units produced during an 8- hr shift Qstd = 8.0(60)/4.00 = 120 work units = 4.00 min
Direct Time Study Direct and continuous observation of a task using a stopwatch or other timekeeping device to record the time taken to accomplish the task While observing and recording the time, an appraisal of the worker s performance level is made to obtain the normal time for the task The data are then used to compute a standard time for the task
Direct Time Study Direct Time Study Procedure 1. Define and document the standard method 2. Divide the task into work elements 3. Time the work elements to obtain the observed time Tobs 4. Evaluate worker s pace relative to standard performance to obtain normal time Tn Called performance rating (PR) Tn = Tobs(PR) 5. Apply allowance factor to compute standard time Tstd = Tn(1 + Apfd)
Direct Time Study Document the Standard Method Determine the one best method Seek worker s advice if possible Documentation should include: All of the steps in the method Special tools, gauges, equipment and equipment settings (e.g., feeds and speeds) if applicable Irregular elements and their frequency Once the standard method is defined, it should not be possible for the operator to make further improvements
Direct Time Study Direct time study form
Direct Time Study Example A direct time study was taken on a manual work element using the snapback method. The regular cycle consisted of three elements, a, b, and c. Element d is an irregular element performed every five cycles. Work element a b Observed time (min) 0.56 0.25 0.50 1.10 Performance rating 100% 80% 110% 100% c d Determine (a) normal time and (b) standard time for the cycle
Direct Time Study (a) Normal time: Tn = 0.56(1.00) + 0.25(0.80) + 0.50(1.0) + 1.10(1.0)/5 = 1.53 min (b) Standard time: Tstd = 1.53(1 + 0.15) = 1.76 min
Work Sampling Statistical technique for determining the proportions of time spent by subjects in various defined categories of activity Subjects = workers, machines Categories of activity = setting up a machine, producing parts, idle, etc. For statistical accuracy Observations must be taken at random times Period of the study must be representative of the types of activities performed by the subjects
Work Sampling When is Work Sampling Appropriate? Sufficient time is available to perform the study Several weeks usually required for a work sampling study Multiple subjects Work sampling suited to studies involving more than one subject Long cycle times for the jobs covered by the study Nonrepetitive work cycles Jobs consist of various tasks rather than a single repetitive task
Work Sampling Example: How Work Sampling Works A total of 500 observations taken at random times during a one-week period (40 hours) on 10 machines with results shown below. Category No. of observations (1) Being set up (2) Running production (3) Machine idle How many hours per week did an average machine spend in each category? 75 300 125 500
Work Sampling Proportions of time determined as number of observations in each category divided by 500 Time in each category determined by multiplying proportion by total hours (40 hr) Category (1) Being set up = 6 (2) Running production = 24 (3) Machine idle Proportion Hrs per category 75/500 = 0.15 0.15 x 40 300/500 = 0.60 0.60 x 40 125/500 = 0.25 0.25 x 40 = 10
Work Sampling Work Sampling Applications Machine utilization - how much time is spent by machines in various categories of activity Previous example Worker utilization - how workers spend their time Allowances for time standards - assessment of delay components in PFD allowance factor Average unit time - determining the average time on each work unit Time standards - limited statistical accuracy when standards set by work sampling
Work Sampling Work Sampling Observation Form
WHERE TO USE MOTION AND TIME STUDY IN YOUR ORGANIZATION Manufacturing Office Banks Department Stores Hospitals
HOW DO YOU DECIDE IF YOU NEED TO DO A MOTION AND TIME STUDY Are production costs too high (is there a problem)? Why is there a problem? How can it be solved? Which alternative is better? Choose the best alternative
AFTER TME STUDY AND LNE BALANC NG Production ncrease %5
Conclusion Motion and time study helps management determine how much is produced by workers in a specific period of time, therefore making it easier to predict work schedules and output. Motion and Time Study is a scientific method designed by two different people for the same purpose, to increase productivity and reduce unit cost. The two methods evaluate work and try to find ways to improve processes.
