Work Study - The American University in Cairo

1 1 October 03 Lotfi K. Gaafar1 Lotfi K. GaafarMethod StudyBased on Introduction to work Study . 3rd ed. International Labor Office, Geneva, 344 Work Analysis and DesignOctober 03 Lotfi K. Gaafar2 Work StudyWork Study is the systematic examination of the methods of carrying on activities so as to improve the effective use of resources and to set up standards of performance for the activities being carried 03 Lotfi K. Gaafar3 Method Study examines the way a task (changing the clutch on a car, preparing a flower bed for planting, cleaning a hotel room)is done. The industrial engineer has an eye on operational efficiencies and costs, quality of processes, service reliability, staff safety etc. Method Study techniques are applicable from factory/workshop manufacturing to cabin crew activities on an international flight and office clerical work.

2 Method StudyA collection of techniques used to examine work -what is done and how it is done -so that there is systematic analysis of all the elements, factors, resources and relationships affecting the efficiency and effectiveness of the work being 03 Lotfi K. Gaafar4 ManagementWorkersSupervisorWork StudySpecialistThe Human Factor in TheApplication of Work Study3 October 03 Lotfi K. Gaafar5 October 03 Lotfi K. Gaafar6 Work Study and the Management Importance of management. How to gain the management support:lMake them feel that it is not their them understand the purpose and techniques of work 03 Lotfi K. Gaafar7 Work Study and the SupervisorThe importance of the supervisor:lMostly affected by work personal are taken 03 Lotfi K.

3 Gaafar8Do s and Don tslNever give a direct order to a refer worker s questions to the express opinions to t allow worker s to get you to alter decisions made by the the supervisor advice whenever be introduced to workers by the Study and the Supervisor5 October 03 Lotfi K. Gaafar9 Work Study and the Worker Work Study improves industrial relations:lWorkers feel that the management cares for discover that there are managers who highly understand their the feeling of are more able to carry out their 03 Lotfi K. Gaafar10 Work Study and the Worker Why workers resist the work Study :lIt will change their familiar work methods. lMany workers resent being of being 03 Lotfi K. Gaafar11 Problem Solving Problem definitionlstatement of purpose, goal, objectivelcriteria of judging successful solutionloutput requirementslcompletion date Analysis of problemlconstraints or specificationsldescription of the present methodlreview problem definition and criteriaOctober 03 Lotfi K.

4 Gaafar12 Problem Solving Search for possible solutionslidentify the basic cause that creates problem;leliminate all unnecessary worklcombine operations or elementslchange sequence of operationslsimplify the necessary operations Evaluation of alternativeslin terms of criteria and original specification7 October 03 Lotfi K. Gaafar13 Problem Solving Recommendation for actionlwritten reports to senior managers lpresentations to senior managers and shop floor employeesldevelopment of soft skills, listening, negotiating, Marketing recommendationsltarget relevant groupsOctober 03 Lotfi K. Gaafar14 How do we measure performance? Profit Financial measures Productivity output/input ratios Cycle time8 October 03 Lotfi K. Gaafar15 Possible Performance Measures Qualityexpressed as % scrap value, % returns, % downtime Costsexpressed as inventory turnover, value added to incoming material Deliveryexpressed as % on time delivery, cycle time Flexibilityas Average number of setups /day, % of common parts/product Innovationas % sales from products introduced in last 3 yearsOctober 03 Lotfi K.

5 Gaafar16 Method StudySelectRecordExamineDevelopEvaluateD efineInstallMaintainTo Simplify the job and develop more economical methods of doing itthe job to be studiedby collecting data or by direct observationby Challenging purpose, place, sequence, and method of worknew methods drawing on contributions of those concernedresults of different alternative solutionsnew method and present itnew method and trainpersons in applying itand establish control procedures9 October 03 Lotfi K. Gaafar17 Select Where to Look Poor use of resources Bad layout Bottlenecks Inconsistent quality High fatiguing work Excessive overtime Employee s complaintsSelectRecordExamineDevelopEval uateDefineInstallMaintainOctober 03 Lotfi K. Gaafar18 Select Economic Considerations Key profit-generating operations Key costly operations Repetitive work Long travels Excessive overtimeSelectRecordExamineDevelopEvalua teDefineInstallMaintainWill it pay to begin, or continue, a method Study of this job?

6 10 October 03 Lotfi K. Gaafar19 Select Technical Considerations Extensive paperwork Repetitive work (automation) Hazardous work Inconsistent qualitySelectRecordExamineDevelopEvaluat eDefineInstallMaintainDesire to acquire more advanced technologyOctober 03 Lotfi K. Gaafar20 Select Human Considerations Satisfaction level Start with non-controversial jobs HSES electRecordExamineDevelopEvaluateDefineI nstallMaintainWorkers satisfaction/resentment11 October 03 Lotfi K. Gaafar21 Select Limiting the Scope One operation or a sequence The whole operation or part Which aspect: worker, materials, equipment, .. boundaries and determining contentOctober 03 Lotfi K. Gaafar22 Select Possible Results Increased production rate Reduced cost Less labor, materials, or equipment Improved quality Improved safety Reduced scrap Improved standards of cleanlinessSelectRecordExamineDevelopEva luateDefineInstallMaintain12 October 03 Lotfi K.

7 Gaafar23 Select Pareto AnalysisSelectRecordExamineDevelopEvalua teDefineInstallMaintainOctober 03 Lotfi K. Gaafar24 Record-SymbolsOperation (Make ready, Do, Put away)InspectionTransportDelayStorageSele ctRecordExamineDevelopEvaluateDefineInst allMaintain13 October 03 Lotfi K. Gaafar25 Record-SymbolsOperation (Make ready, Do, Put away)SelectRecordExamineDevelopEvaluateD efineInstallMaintainOctober 03 Lotfi K. Gaafar26 Record-SymbolsSelectRecordExamineDevelop EvaluateDefineInstallMaintain14 October 03 Lotfi K. Gaafar27 Record-SymbolsSelectRecordExamineDevelop EvaluateDefineInstallMaintainOctober 03 Lotfi K. Gaafar28 Record-SymbolsSelectRecordExamineDevelop EvaluateDefineInstallMaintain15 October 03 Lotfi K. Gaafar29 Record-SymbolsSelectRecordExamineDevelop EvaluateDefineInstallMaintainOctober 03 Lotfi K.

8 Gaafar30 Record-Charts and DiagramsOutline Process ChartFlow Process Chart (Worker, Material, Equipment)Two-Handed Process ChartProcedure ChartSimultaneous motion Cycle ChartMultiple Activity ChartSelectRecordExamineDevelopEvaluateD efineInstallMaintainFlow DiagramString DiagramCyclegraphChronocyclegraphTravel Chart16 October 03 Lotfi K. Gaafar31 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainOutline ChartFace, turn, cutFace opposite endDimension and finishStraddle mill four flatsRemove burrFinal inspection of machiningDegreasingCadmium platingFinal checkFace both sidesDrill holeFinal checkAssemble and drillTurn shankRemove chipDimensionsDegreasingCadmium platingFinal checkFit stop pinFinal checkSwitch RotorOctober 03 Lotfi K.

9 Gaafar32 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintain17 October 03 Lotfi K. Gaafar33 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainOutline ChartOctober 03 Lotfi K. Gaafar34 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainFlow Chart18 October 03 Lotfi K. Gaafar35 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainFlow ChartOctober 03 Lotfi K. Gaafar36 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainFlow Chart19 October 03 Lotfi K. Gaafar37 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainFlow ChartOctober 03 Lotfi K. Gaafar38 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainFlow Chart20 October 03 Lotfi K.

10 Gaafar39 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainMultiple activityChartOctober 03 Lotfi K. Gaafar40 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainString Diagram21 October 03 Lotfi K. Gaafar41 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainString DiagramOctober 03 Lotfi K. Gaafar42 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainTravel Chart22 October 03 Lotfi K. Gaafar43 Record-ExampleSelectRecordExamineDevelop EvaluateDefineInstallMaintainTwo-handed process ChartOctober 03 Lotfi K. Gaafar44 Examine-The QuestionsPurpose:What is actually done?Why is it necessary?Place:Where? Why?Sequence:When? Why?Person:Who? Why?Means:How? Why?SelectRecordExamineDevelopEvaluateDe fineInstallMaintainWith a view to:EliminateCombine or RearrangeSimplify23 October 03 Lotfi K.