3.II Method Study

3. ii 3. ii Method StudyMethod Study

Source: Introduction to Work Study, By International Labour Office, Geneva,

Chp. No. , From Pg No.

Man, Machines, Materials, Money, Technology and Man, Machines, Materials, Money, Technology and Time are the main resources required to produce goods Time are the main resources required to produce goods and are to be deployed in the most effective mannerand are to be deployed in the most effective manner

We have to select the best available combination of We have to select the best available combination of these resources at any point of time.these resources at any point of time.

Method Study helps in analysing the existing Method Study helps in analysing the existing methods and develop a more efficient method for methods and develop a more efficient method for

future.future.

3.ii3.ii Method Study Method Study

Method Study is the systematic recording and critical Method Study is the systematic recording and critical examination of existing and proposed ways of doing examination of existing and proposed ways of doing work, as a means of developing and applying easier work, as a means of developing and applying easier

and more effective methods and reducing costs.and more effective methods and reducing costs.

The objectives of Method Study are :The objectives of Method Study are :– Improvement of processes and proceduresImprovement of processes and procedures– Improvement in the design of plant and equipmentImprovement in the design of plant and equipment– Improvement of plant layout.Improvement of plant layout.– Improvement in the use of men, materials and Improvement in the use of men, materials and

machines.machines.– Efficient materials handlingEfficient materials handling

3.2.A Definition And Objective of Method Study3.2.A Definition And Objective of Method Study

– Improvement in the flow of production and Improvement in the flow of production and process.process.

– Economy in human effort and the reduction of Economy in human effort and the reduction of unnecessary fatigue.unnecessary fatigue.

– Method StandardizationMethod Standardization– Improvement in safety standards.Improvement in safety standards.– Development of a better physical working Development of a better physical working

environmentenvironment

Definition And Objective of Method StudyDefinition And Objective of Method Study

Good working conditions contribute to improvement Good working conditions contribute to improvement in productivity.in productivity.

The following are a fewThe following are a few

– Occupational safety and health conditionsOccupational safety and health conditions– Fire prevention and protectionFire prevention and protection– Layout and house keeping (5S)Layout and house keeping (5S)– Lighting and VentilationLighting and Ventilation– Noise and VibrationNoise and Vibration– ErgonomicsErgonomics– Arrangement of working TimeArrangement of working Time

Working Conditions And InfluenceWorking Conditions And Influence

The solution of any problem follows the The solution of any problem follows the following sequence of phases in that orderfollowing sequence of phases in that order : :

1)1) Define: Define: The problem.The problem.2)2) Record: Record: All the facts relevant to the problem.All the facts relevant to the problem.3)3) Examine: Examine: The facts critically but impartially.The facts critically but impartially.4)4) Consider: Consider: The courses of actions (possible The courses of actions (possible

solutions) and decide which to follow.solutions) and decide which to follow.5)5) Implement:Implement: The solution.The solution.6)6) Follow Up:Follow Up: The development.The development.

The basic procedure for the whole of work The basic procedure for the whole of work study, which embraces the procedures of both study, which embraces the procedures of both method study and work measurement.method study and work measurement. Contd… Contd…

ProcedureProcedure

Steps and Procedure to conduct Method Steps and Procedure to conduct Method Study :Study :

a)a) Select: Select: the work to be studied.the work to be studied.b)b) RecordRecord: : all the relevant facts about the all the relevant facts about the

present method by direct observation.present method by direct observation.c)c) ExamineExamine: : those facts critically and in an those facts critically and in an

orderly sequence, using the techniques orderly sequence, using the techniques best suited to the purpose.best suited to the purpose.

d)d) DevelopDevelop: : the most practical, economic and the most practical, economic and effective method, having due regard to all effective method, having due regard to all contingent circumstances.contingent circumstances.

Procedure…Procedure…

e)e) Define: Define: the new method so that it can the new method so that it can always be identified.always be identified.

f)f) Install: Install: that methods as standard practice.that methods as standard practice.

g)g) Maintain: Maintain: that standard practice by regular that standard practice by regular routine checks.routine checks.

These are the seven essential stages in the These are the seven essential stages in the application of method study ; none can be application of method study ; none can be

excluded. Strict adherence to the sequence, as excluded. Strict adherence to the sequence, as well as to their content, is essential for the well as to their content, is essential for the

success of an investigation. They are shown success of an investigation. They are shown diagrammatically on the chart.diagrammatically on the chart.

Procedure…Procedure…

Method StudyMethod StudyRecord

At Work Place By means of

At Work Place

By means of

Examine the facts critically

Two handed ; Simo ; Multiple Activity

Charts

Other MeansCycle Graphs ; Chronocycle Graphs ;Film Analysis ; Memotion Photography

Select

Define Scope of Study

Work which can be studiedWith economic advantage

Charts

Other Means

Outline Process ;Flow Process – Man type , Material type ;Multiple Activity ; TravelFlow Diagrams ; String Diagrams ; Models

Challenge

PURPOSE – PLACE – SEQUENCE – PERSON - MEANS

Seek Alternatives

Find PointersCombine or

ChangeSimplifyEliminat

eDevelopA record of an improved

methodRe - Examinethat record to

establish

Method Study to improve

methods of production

The Best Method under Prevailing Circumstances

Planning and ControlMaterials HandlingGeneral Environment and Working ConditionsPlant Layout

Mechanical Aids ; Manual Controls and Visual instrumentsEquipment design ; Jigs and fixturesLocal Working Conditions

Define

InstallThe Improved method

Plan - Arrange - Implement

MaintainVerify at regular intervals that

The important method as defined is in fact in use

To achieve improved factory and work space

layoutImproved design of equipment

Better working conditionsReduction of fatigue

Resulting in improved use of materialPlant and equipment

manpower

HigherProductivity

Factors o be considered in selecting a job for Factors o be considered in selecting a job for method study:method study:

Economic Consideration.Economic Consideration.Technical Consideration.Technical Consideration.Human Reactions.Human Reactions.Economic Consideration.Economic Consideration.

The cost of the study should be estimated and The cost of the study should be estimated and examined: examined: short-term & Long-term.short-term & Long-term.

The loss of time due to the investigation.The loss of time due to the investigation.For any job, if accumulated estimated benefits For any job, if accumulated estimated benefits

from the recommended method outweighs the from the recommended method outweighs the estimated total cost then we should take-up the estimated total cost then we should take-up the job under study – Discounted Cash Flow job under study – Discounted Cash Flow Technique (DCF) or Pay-back period method Technique (DCF) or Pay-back period method may be used for this purpose.may be used for this purpose.

Selection Of JobSelection Of Job

Under Preliminary Considerations, the early job Under Preliminary Considerations, the early job choices are:choices are: Bottlenecks:Bottlenecks: which are holding up other which are holding up other

production operations.production operations. Movements of material over long Movements of material over long

distances:distances: between shops or operations between shops or operations involving a great deal of manpower or where involving a great deal of manpower or where there is repeated handling of material.there is repeated handling of material.

Operations involving repetitive work:Operations involving repetitive work: using a great deal of labour liable to run for using a great deal of labour liable to run for a long time.a long time.

Selection Of Job…Selection Of Job…

Technical Considerations: Technical Considerations: Make sure that Make sure that adequate technical knowledge is available with adequate technical knowledge is available with which to carry out the study.which to carry out the study.

Human Reactions: Human Reactions: These are the most These are the most important factors to be taken into consideration important factors to be taken into consideration since mental and emotional reactions to since mental and emotional reactions to investigation, and change of method have to be investigation, and change of method have to be anticipated.anticipated.

Selection Of Job…Selection Of Job…

The Field Of ChoiceThe Field Of Choice

Types of Jobs Examples Recording Technique

Complete Sequence of manufacture

Manufacture of an electric motor from raw material to dispatchTransformation of thread into cloth from preparation to inspectionReceipt, packing and dispatch of fruit

Outline process chartFlow process chartFlow diagram

Factory layout : movement of materials

Movements of a diesel engine cylinder head through all machining operations. Movements of grain between milling operations

Outline process chartFlow process chart–material typeFlow diagramTravel chartModels

The Field Of Choice…The Field Of Choice…


Factory layout : movement of workers

Labourers servicing spinning machine with bobbinsCooks preparing meals in a restaurant kitchen

Flow process chart-man type string diagramString diagram

Handling of materials

Putting materials into and taking them out of storesLoading lorries with finished products.

Flow process chart – material typeFlow diagramString diagram

Workplace layout

Light assembly work on a benchTypesetting by hand

Flow process chart-man type. Two-handed process chart. Multiple activity chart. Simo chart. Cyclegraph.Chronocyclegraph.


Gang work or automatic machine operation

Assembly line Operator looking after semi-automatic lathe

Multiple activity chartFlow process chart-equipment type

Movements of operatives at work

Female operatives on short – cycle repetition workOperations demanding great manual dexterity

Multiple activity chartFlow process chart – equipment typeFilmsFilm analysisSimo chartMemotion photographyMicromotion analysis


When selecting a job for method study it will be found helpful to have a standerdised list of

points to be covered as shown below :-

1.1. Product and operationProduct and operation2.2. Person who proposes investigationPerson who proposes investigation3.3. Reason for proposalReason for proposal4.4. Suggested limits of investigationSuggested limits of investigation5.5. Particulars of the jobParticulars of the job

a)a) How much is produced or handled How much is produced or handled per week?per week?


b)b) What percentage (roughly) is this of the total What percentage (roughly) is this of the total produced or handled in the shop or plant?produced or handled in the shop or plant?

c)c) How long will the job continue?How long will the job continue?d)d) Will more or less be required in future?Will more or less be required in future?e)e) How many operatives are employed on the How many operatives are employed on the

job job i.i. Directly?Directly?ii.ii. Indirectly?Indirectly?

f)f) How many operatives are there in each How many operatives are there in each grade and on each rate of pay?grade and on each rate of pay?

g)g) What is the average output per operative What is the average output per operative (per team) per day?(per team) per day?

h)h) What is the daily output compared with the What is the daily output compared with the output over a shorter period? (e.g. an hour)output over a shorter period? (e.g. an hour)


i)i) How is payment made? (team-work, How is payment made? (team-work, piece-work, premium bonus time rate, piece-work, premium bonus time rate, etc)etc)

j)j) What is the daily output –What is the daily output –i.i. Of the best operative?Of the best operative?ii.ii. Of the worst operative?Of the worst operative?

k)k) When were production standards set?When were production standards set?l)l) Has the job any especially unpleasant or Has the job any especially unpleasant or

injurious features? Is it unpopularinjurious features? Is it unpopulari.i. With workers ?With workers ?ii.ii. With supervisors ?With supervisors ?


6.6. Equipment.Equipment.a)a) What is the approximate cost of plant and What is the approximate cost of plant and

equipment?equipment?b)b) What is the present machine utilisation What is the present machine utilisation

index?index?7.7. LayoutLayout

a)a) Is the existing space allowed for the job Is the existing space allowed for the job enough?enough?

b)b) Is extra space available ?Is extra space available ?8.8. Product.Product.

a)a) Are the frequent design changes causing Are the frequent design changes causing modifications ?modifications ?

b)b) Can the product be altered for easier Can the product be altered for easier manufacture ?manufacture ?

c)c) When and how is product inspected ?When and how is product inspected ?d)d) What quality is demanded ?What quality is demanded ?


9.9. What savings or increase in productivity What savings or increase in productivity may be expected from a method may be expected from a method improvement ?improvement ?a)a) Through reduction in the work content Through reduction in the work content

of the product or process.of the product or process.b)b) Through better machine utilisation.Through better machine utilisation.c)c) Through better use of labourThrough better use of labour

Contd…Contd…


It is important to set clearly defined limits to the It is important to set clearly defined limits to the scope of the investigationscope of the investigation

Method study investigations so often reveal Method study investigations so often reveal scope for even greater savings that there is a scope for even greater savings that there is a strong temptation to go beyond the immediate strong temptation to go beyond the immediate objectiveobjective

This should be resisted, and any jobs shown This should be resisted, and any jobs shown up as offering scope for big improvements up as offering scope for big improvements through method study should be noted and through method study should be noted and tackled separately.tackled separately.

““Do not use a spoon when a steam shovel is Do not use a spoon when a steam shovel is needed”needed”


After selecting the work to be studiedAfter selecting the work to be studied

Systematic recording of all the existing method and Systematic recording of all the existing method and critical examination of these are carried out to critical examination of these are carried out to eliminate every unnecessary element or operation and eliminate every unnecessary element or operation and to develop the quickest and best method by having an to develop the quickest and best method by having an improved sequence of doing the work, omitting the improved sequence of doing the work, omitting the redundant elements, selecting more appropriate redundant elements, selecting more appropriate person and more suitable place for doing the work.person and more suitable place for doing the work.

Is to record all the facts relating to the existing Is to record all the facts relating to the existing method. The success of the whole procedure depends method. The success of the whole procedure depends on the accuracy with which the facts are recorded, on the accuracy with which the facts are recorded,

Record, Examine, DevelopRecord, Examine, Develop

because they will provide the basis of both the critical because they will provide the basis of both the critical examination and the development of the improved examination and the development of the improved method. It is therefore essential that the record be clear method. It is therefore essential that the record be clear and concise.and concise.

The usual way of recording facts is to write them down. The usual way of recording facts is to write them down. Unfortunately, this method is not suited to the recording Unfortunately, this method is not suited to the recording of the complicated processes which are so common in of the complicated processes which are so common in modern industry.modern industry.

To overcome this difficulty other techniques or To overcome this difficulty other techniques or `tools’ of recording have been developed, so `tools’ of recording have been developed, so that detailed information may be recordedthat detailed information may be recorded

Record, Examine, Develop…Record, Examine, Develop…

precisely and at the same time in a standard precisely and at the same time in a standard form, in order that it may be readily form, in order that it may be readily understood by all method study men, in understood by all method study men, in whatever factory or country they may be whatever factory or country they may be working.working.

The most commonly used of these recording The most commonly used of these recording techniques are charts and diagrams.techniques are charts and diagrams.

There are several different types of standard There are several different types of standard charts available, each with its own special charts available, each with its own special purposes.purposes.


Two groups of charts :Two groups of charts :

Those which are used to record a process Those which are used to record a process sequence, i.e., a series of events or sequence, i.e., a series of events or happenings in the order in which they happenings in the order in which they occur, but which do not depict the events to occur, but which do not depict the events to scale; andscale; and

Those which record events, also in Those which record events, also in sequence, but on a time scale, so that the sequence, but on a time scale, so that the interaction of related events may be more interaction of related events may be more easily studied. easily studied.


The most commonly used method study charts and diagramsThe most commonly used method study charts and diagrams

A. Charts Indicating process SEQUENCEOutline Process ChartFlow Process Chart – Man TypeFlow Process Chart – Material TypeFlow Process Chart – Equipment TypeTwo – Handed Process Chart

B. Charts Using a TIME SCALEMultiple Activity ChartSimo Chart

C. Diagrams Indicating movementFlow DiagramString DiagramCyclegraphChromocyclegraphTravel Chart


The recording of the facts about a job or The recording of the facts about a job or operation on a process chart is made much operation on a process chart is made much easier by the use of a set of standard easier by the use of a set of standard symbols, which together serve to represent all symbols, which together serve to represent all the different types of activity or event likely to the different types of activity or event likely to be encountered in any factory or office.be encountered in any factory or office.

The two principal activities in a process are The two principal activities in a process are operation and inspection.operation and inspection.

3.ii.B3.ii.B Symbols used in Method Study Symbols used in Method Study

Process Chart Symbols…Process Chart Symbols…

Indicates the main steps in a process, method or procedure.Indicates the main steps in a process, method or procedure.Usually the part, material or product concerned is modified or Usually the part, material or product concerned is modified or

changed during the operation. changed during the operation.

InspectionInspection

Indicates an inspection for quality and / or check for quantityIndicates an inspection for quality and / or check for quantity

OperationOperation

TransportTransport

Indicates the movement of workers, materials or equipment from place Indicates the movement of workers, materials or equipment from place to placeto place

Temporary Storage or DelayTemporary Storage or Delay

Indicates a delay in the sequence of events : for example, work waiting Indicates a delay in the sequence of events : for example, work waiting between consecutive operations, or any object laid aside temporarily without between consecutive operations, or any object laid aside temporarily without

record until required. record until required.

Permanent StoragePermanent Storage

Indicates a controlled storage in which material is received into or issued Indicates a controlled storage in which material is received into or issued from a store under some form of authorization; or an item is retained for from a store under some form of authorization; or an item is retained for reference reference purposes.purposes.

Combined ActivitiesCombined Activities

Indicates a controlled storage in which material is received into or issued Indicates a controlled storage in which material is received into or issued from a store under some form of authorization; or an item is retained for from a store under some form of authorization; or an item is retained for reference reference purposes.purposes.

Process Chart Symbols…Process Chart Symbols…

3.ii.C3.ii.C The Outline Process ChartThe Outline Process Chart

The Outline Process ChartThe Outline Process Chart

In an outline process chart, only the principal In an outline process chart, only the principal operations and the inspections carried out are operations and the inspections carried out are recorded to ensure effectivenessrecorded to ensure effectivenessWhile preparing the outline process chart we use While preparing the outline process chart we use Symbols of Operation and InspectionSymbols of Operation and InspectionA brief note of the nature of each operation is made A brief note of the nature of each operation is made beside the symbolbeside the symbol

An outline process chart is a process chart An outline process chart is a process chart giving an overall picture by giving an overall picture by recording in sequence recording in sequence only the main operations and inspectionsonly the main operations and inspections..

ExampleExample

Assembling a switch rotorAssembling a switch rotor

Switch Rotor AssemblySwitch Rotor Assembly

The operations and inspections carried out on the The operations and inspections carried out on the spindle made from 10mm spindle made from 10mm ØØ steel rod are as follows steel rod are as follows

O 1O 1 Face, turn, undercut and part off on capstan latheFace, turn, undercut and part off on capstan lathe(0.025 (0.025 hrs)hrs)

O 2O 2 Face opposite end on the same machine(0.010 Face opposite end on the same machine(0.010 hrs). hrs). Transport to inspn deptTransport to inspn dept

I 1I 1Inspect for dimensions and finish (no time fixed). Inspect for dimensions and finish (no time fixed). Transport to milling sectionTransport to milling section

O 3 O 3 Straddle mill four flats on end on a horizontal Straddle mill four flats on end on a horizontal miller miller (0.020 hrs). Transport to work (0.020 hrs). Transport to work benchbench

O 4 O 4 Remove burrs at the burring bench(0.020 hrs). Remove burrs at the burring bench(0.020 hrs). Transport to inspn deptTransport to inspn dept

I 2 I 2 Final inspn of machine (no time)Final inspn of machine (no time)

O5 O5 Degreasing(0.0015 hrs)Degreasing(0.0015 hrs)O6 O6 Cadmium plating(.008 hrs)Cadmium plating(.008 hrs)I3 I3 Final check (no time)Final check (no time)O7 O7 Face on both sides, bore the cored hole and ream Face on both sides, bore the cored hole and ream

to to size on a capstan lathe(0.080 hrs)size on a capstan lathe(0.080 hrs)O8 O8 Drill cross-hole and burr on two-spindle drill Drill cross-hole and burr on two-spindle drill

press(0.022 hrs)press(0.022 hrs)I4 I4 Final check dimensions and finish (no time)Final check dimensions and finish (no time)

Transport to finished parts stores and await with-Transport to finished parts stores and await with-drawl drawl for assembly.for assembly.

Note the numbering of operations and inspectionsNote the numbering of operations and inspections

Outline process chartOutline process chart

Outline process chartOutline process chart

In making an outline process chart we In making an outline process chart we start with a vertical line down the right start with a vertical line down the right hand side of the page to show the hand side of the page to show the operations and inspections undergone.operations and inspections undergone.

The time allowed per piece is also shown The time allowed per piece is also shown on the left hand side.on the left hand side.

3.ii.D3.ii.D FLOW PROCESS CHARTFLOW PROCESS CHART

Process activity symbolsProcess activity symbols

– OperationOperation

– InspectionInspection

– TransportTransport

– Temporary storage or DelayTemporary storage or Delay

– Permanent storagePermanent storage

Process chart symbols Process chart symbols

Used to represent different types of Used to represent different types of activities or events.activities or events.

Very convenient, widely understood type Very convenient, widely understood type of short hand, saves a lot of writing and of short hand, saves a lot of writing and helps in making the sequence of helps in making the sequence of activities clear.activities clear.

3.ii.D Flow process chart3.ii.D Flow process chart 2/62/6

A FLOW PROCESS CHART records what A FLOW PROCESS CHART records what the worker does.the worker does.

It is a chart setting out the frequency of It is a chart setting out the frequency of flow of a product or procedure by recording all flow of a product or procedure by recording all events under review using process chart events under review using process chart symbols.symbols.

there are different types of flow process there are different types of flow process charts.charts.

PurposePurpose::

To set out the sequence of the flow of a To set out the sequence of the flow of a product or a procedure by recording all the product or a procedure by recording all the events under review events under review

( Inspection ) using the appropriate process ( Inspection ) using the appropriate process chart symbols.chart symbols.

Activities recorded in the flow chartActivities recorded in the flow chart

Those where some thing is happening to Those where some thing is happening to the work piece.the work piece.

Those where the work piece is not Those where the work piece is not touched – (stored or standstill)touched – (stored or standstill)

Three types of flow process chartsThree types of flow process charts

Man typeMan type– Flow chart which records what the worker doesFlow chart which records what the worker does

Material typeMaterial type– Flow chart which records how material is handled or Flow chart which records how material is handled or

treatedtreated

Equipment typeEquipment type– Flow chart which records how the equipment is Flow chart which records how the equipment is

usedused

FLOW PROCESS CHART FOR FLOW PROCESS CHART FOR ENGINE ENGINE

Stripping – Cleaning - GreasingStripping – Cleaning - Greasing

Critical ExaminationCritical Examination

The questioning technique is the critical means The questioning technique is the critical means by which the critical examination is conducted by which the critical examination is conducted – each activity being subjected in turn to a – each activity being subjected in turn to a systematic and progressive series of questionssystematic and progressive series of questions

OPERATIONSOPERATIONS

Make ReadyMake Ready

DoDo

Put AwayPut Away

Make ready and put away operations can Make ready and put away operations can be represented by transport and be represented by transport and inspection symbols inspection symbols

DO operations can be shown by “O”DO operations can be shown by “O”

CRITICAL EXAMINATIONCRITICAL EXAMINATION- - Primary questionsPrimary questions

The Purpose The Purpose for which…for which…

The Place The Place at which…at which…

The sequence The sequence in which…in which…

The person The person by which…by which…

The means The means by which…by which…

……the activities are undertakenthe activities are undertaken

CRITICAL EXAMINATIONCRITICAL EXAMINATION- - Primary questionsPrimary questions

With a view toWith a view to

EliminatingEliminatingCombiningCombiningRearrangingRearrangingSimplifyingSimplifying

……those Activitiesthose Activities

PRIMARY QUESTIONSPRIMARY QUESTIONS

PURPOSEPURPOSE ELIMINATEELIMINATE

PLACEPLACE COMBINECOMBINE

SEQUENCESEQUENCE REARRANGEREARRANGE

PERSON PERSON REARRANGEREARRANGE

MEANSMEANS SIMPLIFYSIMPLIFY

THE SECONDARY QUESTIONSTHE SECONDARY QUESTIONS

DefinitionDefinition The secondary questions cover the second The secondary questions cover the second

stage of the questioning technique, during stage of the questioning technique, during which the answers to the primary which the answers to the primary questions are subjected to further query to questions are subjected to further query to determine whether possible alternatives to determine whether possible alternatives to place, sequence, persons and/or means place, sequence, persons and/or means are practicable or preferable as the means are practicable or preferable as the means of improvement up on the existing methodof improvement up on the existing method

SECONDARY QUESTIONS…SECONDARY QUESTIONS…

During the second stage During the second stage of questioning, we should of questioning, we should addressaddress– What else might be done?What else might be done?– What should be done?What should be done?

PurposePurposePlacePlaceSequenceSequencePersonPersonMeans Means

These questions are the These questions are the basis for a systematic basis for a systematic method study.method study.

EXAMPLE: ENGINE EXAMPLE: ENGINE Stripping – Cleaning - DegreasingStripping – Cleaning - Degreasing

DEVELOP DEVELOP IMPROVED METHODIMPROVED METHOD

After critically examining and After critically examining and sequential questioning we sequential questioning we develop the improved method develop the improved method and record the improved method and record the improved method in a flow process chart as shownin a flow process chart as shown

1.1. String diagramString diagram

2.2. Flow Process chartFlow Process chart

3.3. Travel ChartTravel Chart

4.4. Flow diagramFlow diagram

5.5. Multiple activity chartMultiple activity chart

6.6. Template ModelsTemplate Models

TOOLS USED FOR PREPARING TOOLS USED FOR PREPARING PLANT LAYOUTSPLANT LAYOUTS

3.ii.D.1 String diagram3.ii.D.1 String diagram 1/61/6

String diagram is a useful tool to record the String diagram is a useful tool to record the distance traveled by a worker in the working area. distance traveled by a worker in the working area. The string diagram is a scale plan or model on The string diagram is a scale plan or model on which a thread is used to trace and measure the which a thread is used to trace and measure the distance traversed which has to be distance traversed which has to be minimumminimum by by

•WorkersWorkers•Material orMaterial or•Equipment Equipment

during a specified sequence of eventsduring a specified sequence of events

Observe the clusters of points, pins, turning Observe the clusters of points, pins, turning points. points.

Also observe the grid lines which represent a Also observe the grid lines which represent a measure of the distance between the points.measure of the distance between the points.

Construction of a String diagramConstruction of a String diagram

Step-1Step-1– Preparing a study chartPreparing a study chart

Step-2Step-2 – Drawing a scale plan of the working areaDrawing a scale plan of the working area

Step-3Step-3– Combining steps 1,2 to construct the final diagramCombining steps 1,2 to construct the final diagram

Step-1Step-1:: Preparing a study chart Preparing a study chart

Worker being studied is followed and all the Worker being studied is followed and all the points along the working areas are noted in a points along the working areas are noted in a study sheet until a representative picture of the study sheet until a representative picture of the workers is obtained.workers is obtained.

Thus the movements are noted down for Thus the movements are noted down for enough number of cycles so as to capture the enough number of cycles so as to capture the actual work in terms of the journey made by the actual work in terms of the journey made by the worker with their respective frequencies.worker with their respective frequencies.

Step-2Step-2:: Drawing a scale plan of the Drawing a scale plan of the working areaworking area

Machines, benches, stores and all other points Machines, benches, stores and all other points at which calls are made are drawn to scale at which calls are made are drawn to scale together with doorways, pillars etc that effect together with doorways, pillars etc that effect the path movements.the path movements.

Then attachments like soft wood, composition Then attachments like soft wood, composition board and pins are driven firmly at every point. board and pins are driven firmly at every point. Pins are driven also at turning points on the Pins are driven also at turning points on the route.route.

This ensures a shop floor environment which This ensures a shop floor environment which helps to do the study accurately.helps to do the study accurately.

Step-3Step-3:: Combining the steps 1 and Combining the steps 1 and 22

A measured length of thread is wound from the A measured length of thread is wound from the starting point of the movement of the worker starting point of the movement of the worker and leading through all the points on the path of and leading through all the points on the path of the worker in the same order noted in the step-the worker in the same order noted in the step-11

This results in a String diagram.This results in a String diagram.

Example of a String diagramExample of a String diagramMovement, Transport of tiles from Inspection to Movement, Transport of tiles from Inspection to

StorageStorage

IMPROVED METHODIMPROVED METHOD

Serving dinners in a hospital wardServing dinners in a hospital ward

FPC - FPC - Dinners in a hospital Dinners in a hospital wardward

Original Flow Diagram Inspn and MarkingOriginal Flow Diagram Inspn and Marking

Improved FD of Inspection and Improved FD of Inspection and MarkingMarking

3.ii.D.iii Travel chart3.ii.D.iii Travel chart 3/63/6

A travel chart is a tabular record for A travel chart is a tabular record for presenting quantitative data about the presenting quantitative data about the movements of workers, materials or movements of workers, materials or equipment between any number of places equipment between any number of places over any given period of time.over any given period of time.

Why Travel chart ?Why Travel chart ?

Although the string diagram is a neat and Although the string diagram is a neat and effective way of record the movement of worker effective way of record the movement of worker or material for critical examination, or material for critical examination, o they take long time to construct they take long time to construct o look increasingly like a complex maze with look increasingly like a complex maze with

increasing complexity of movement pathsincreasing complexity of movement paths

When the movement patterns are complex, the When the movement patterns are complex, the travel chart is quicker and more manageable to travel chart is quicker and more manageable to record. record.

More about Travel chartMore about Travel chart

Always a squareAlways a square

A column at (m,n) is checked only when there A column at (m,n) is checked only when there is a direct movement from station at m to is a direct movement from station at m to station at n directly.station at n directly.

The number of times a column at (m,n) is The number of times a column at (m,n) is checked over a period of time gives the checked over a period of time gives the frequency of movement of a worker or material.frequency of movement of a worker or material.

The matrix is always a symmetrical matrix. The matrix is always a symmetrical matrix.

Travel chartTravel chart

3.ii.D.4 FLOW DIAGRAM3.ii.D.4 FLOW DIAGRAMWhile the flow process chart describes the flow of a While the flow process chart describes the flow of a product or process, it is generally supplemented with a product or process, it is generally supplemented with a flow diagram.flow diagram.While the flow process chart records travel distances While the flow process chart records travel distances and time taken for various operations, the flow diagram and time taken for various operations, the flow diagram is a plan , drawn to scale of the work area, correctly is a plan , drawn to scale of the work area, correctly indicating the position of machines and working indicating the position of machines and working positions.positions.The symbols are also indicated in the flow diagram.The symbols are also indicated in the flow diagram.The example shown indicates the flow diagram of receiving, The example shown indicates the flow diagram of receiving,

inspection, marking and storing materials.inspection, marking and storing materials.After recording examining and developing a new method, the After recording examining and developing a new method, the

improved flow diagram shows the transport operations reduced improved flow diagram shows the transport operations reduced from a 11 to 6. delays from 7 to 2. and the distance travelled from a 11 to 6. delays from 7 to 2. and the distance travelled reduced from 56.2 to 32.2reduced from 56.2 to 32.2

Original Flow Diagram Inspection and MarkingOriginal Flow Diagram Inspection and Marking

Improved FD of Inspection and Improved FD of Inspection and MarkingMarking

3.ii.E.3.ii.E.

MULTIPLE ACTIVITY CHART MULTIPLE ACTIVITY CHART

Multiple activity chart is a useful recording tool Multiple activity chart is a useful recording tool for situations where the work involves the for situations where the work involves the interaction of different persons. Such as the interaction of different persons. Such as the operator working on different machines.operator working on different machines.In Mac a time scale is used.In Mac a time scale is used.Mac can be used effectively even if there is no Mac can be used effectively even if there is no movement of workers involved in the work under movement of workers involved in the work under consideration.consideration.Focus on Mac in situations where the operator Focus on Mac in situations where the operator are moving and to identify the idle time of the are moving and to identify the idle time of the worker or the machineworker or the machine

Multiple activity chartMultiple activity chart

A MULTIPLE ACTIVIITY chart is a chart in which A MULTIPLE ACTIVIITY chart is a chart in which the activities of more than one subject (worker, the activities of more than one subject (worker, machine or item of equipment) are each machine or item of equipment) are each recorded on a common time scale to show their recorded on a common time scale to show their inter relationship.inter relationship.By using separate vertical columns or bars, to By using separate vertical columns or bars, to represent the activities of different operatives or represent the activities of different operatives or machines against a common time scale, the machines against a common time scale, the chart shows very clearly periods of idleness on chart shows very clearly periods of idleness on the part of any of the subjects during the the part of any of the subjects during the process.process.

Inspection of catalyst in a converterInspection of catalyst in a converter

The following slides show the present method of The following slides show the present method of inspecting catalyst in a convertor where teams of inspecting catalyst in a convertor where teams of electrician and mate, fitter and mate, rigger and electrician and mate, fitter and mate, rigger and process man are working together. process man are working together.

In the original method it took 6 mins for the In the original method it took 6 mins for the inspn. inspn.

After recording, critically examining and After recording, critically examining and developing a new method, the inspection time is developing a new method, the inspection time is reduced to four minute,ie a 32% saving.reduced to four minute,ie a 32% saving.

MAC-Inspn of catalyst in a converter-MAC-Inspn of catalyst in a converter-original methodoriginal method

MAC-Inspn of catalyst in a converter-MAC-Inspn of catalyst in a converter-Improved methodImproved method

3.ii.F TEMPLATE MODELS3.ii.F TEMPLATE MODELS

Template models are used to study the Template models are used to study the layout and the positioning of various layout and the positioning of various machines by pasting templates on the machines by pasting templates on the plant layout diagram.plant layout diagram.

This can be extended by using the string This can be extended by using the string diagram technique to visualize the flow of diagram technique to visualize the flow of the material.the material.

3.II Method Study

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