WORK STUDY procedure.docx
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WORK STUDY procedure.docx
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WORKSTUDYprocedure
Edition
Date
Changedescription
Issuedby
Approvedby
01
22.02.2011
Firstissue
D.Bartyzel
M.Malik
CONTENTS
1.INTRODUCTION1
2.SCOPE1
3.TERMINOLOGY1
4.RESPONSIBILITY16
5.POLICY16
6.REFERENCES17
1.INTRODUCTION
ThepurposeofthisprocedureistodefinethemethodologyofworkstudyinBoryszew/MaflowGroup.
2.SCOPE
TheprocedureappliestoallMaflowplantsanddefines:
-WORKSTUDY
-METHODSTUDY
-WORKMEASUREMENT
3.TERMINOLOGY
a)Terms:
WORKSTUDY–istheexaminationofthemethodsofperformingactivitiestoimprovetheeffectiveuseofallresourcesandtosetupstandardsofperformancefortheseactivities.Workstudyconsistsof2techniques:
methodstudyandworkmeasurement.
METHODSTUDY-isthesystematicrecordingandcriticalexaminationofwaysofperformingoperationsinordertomakeimprovements.
WORKMEASUREMENT-istheapplicationoftechniquesdesignedtoestablishthetimeforaqualifiedworkerperformingoperationsatadefinedrateofworking.
OPERATION–isaseriesofprocessingphasesnecessarytotransformtheproductandcanbecarriedoutbytheoperatorormachineorbothinthesameworkplace.Operationmayconsistofaddedvalueandnotaddedvalue.
RATING–isatermusedinworkmeasurementtoassessthespeedandeffortputtedintoajoborworkbytheworker.
STANDARDPERFORMANCE–istherateofoutputwhichqualifiedworkerswillnaturallyachievewithoutover-exertionasanaverageovertheworkingdayorshift,providedthattheyknowandabidethespecifiedmethodandprovidedthattheyaremotivatedtoapplythemselvestotheirwork.Thisperformanceissetas100onthestandardratingandperformancescales.
BASICTIME-representsthetimetheoperationswouldtaketoperform(inassessmentoftheworkstudyperson)iftheoperatorwasworkingatthestandardrate,insteadofthefasteronewhichwasobserved.
ALLOWANCES–additionaltimeforlaborfatigue,personalneed,periodicaloperations.
MACHINETIME–(TM)minimumtheoreticalmachinetimeinwhichoperationcanbecompletedwithpreservationofqualitystandards.
MACHINESHUTDOWNTIME–(MF)timeofalloperations(plusallowancefactors)performedmanuallybytheoperatorduringmachinestoppage.
MACHINEOPERATINGTIME–(ML)timeofalloperations(plusallowancefactors)performedmanuallybytheoperatorduringmachinework.
TIMECYCLE–(TC)standardtime-minimumtheoreticaltimeinwhichoperationcanbecompleted.Itsvalueisobtainedfromtheexpression:
TC=TM+MF.
b)Abbreviations:
TM–machinetime[min]
MF–machineshutdowntime[min]
ML–machineoperatingtime[min]
TC–timecycle–standardtime[min]
c)Methodology:
General
Theproblemwiththebaseforthecalculationoftheproductcostisthatthecostsdetectedandaggregatedduetothenatureoftraditionalaccountingsystemshavetobelinkedtotheproductunit.Theneedtoestablishthecalculationonaunitbasisistheoriginalaspectoftheentiremeasurementprocess.
Theproblemsinvolvedindeterminingtheproductcostsrelatetothequantificationofthetwocomponents–thedirectandindirect.
Thisproceduredealswiththedirectcomponent.
Workstudy
Methodstudyandworkmeasurementarecloselylinked.Methodstudyisconcernedwiththereductionoftheworkcontentofajoboroperation,whileworkmeasurementismostlyconcernedwithestablishmentoftimestandardsfortheoperationperformedintheimprovedwaydeterminedbymethodstudy.Methodstudyshouldprecedetheuseofworkmeasurement.
Basicsequenceofworkstudy
Thereareeightstepsinperformingacompleteworkstudy:
1.Selecttheworkorprocesstobestudied.
2.Recordorcollectallrelevantdataaboutjoborprocessinthemostconvenientformforanalysis.
3.Examinetherecordedfactscriticallyandchallengeeverythingthatisdone:
purposeoftheactivity,placewhereitisperformed,sequenceinwhichitisdone,personwhoisdoingit,meansbywhichitisdone.
4.Developthemosteconomicmethod,takingintoaccountallthecircumstances,techniques,contributionsofmanagers,supervisors,workersandotherspecialistswithwhomnewapproachescouldbediscussed.
5.Evaluatetheresultsattainedbytheimprovedmethodincomparisontothequantityofworkinvolvedandcalculateastandardtimeforit.
6.Definethenewmethodandtherelatedtimeandpresentittoallthoseconcerned.
7.Installthenewmethod,trainingthoseinvolved.
8.Maintainthenewstandardpracticebymonitoringtheresultsandcomparingthemwiththeoriginaltargets.
Steps1,2,3concernbothmethodstudyandworkmeasurement.Step4ispartofmethodstudypractice,whilestep5belongstoworkmeasurement.Itispossiblethatafteracertaintimethenewmethodneedsamodification,inthiscaseitshouldbere-examinedagainusingtheabovesequence.
Workstudyisverypowerfultoolofinvestigation,becauseawell-conductedworkstudyanalysisisruthlesslysystematic,theplaceswhereeffortandtimewerewastedarediscoveredonebyone.
Savoir–Vivreforworkstudyperson.
Workstudyperson–supervisor:
Theworkstudypersontohavegoodrelationshipwithsupervisorsmustabidesomerules:
1.Theworkstudypersonmustnevergiveadirectordertoaworker.Allinstructionsshouldbegiventhroughthesupervisor.Exceptionisinmattersconnectedwithmethodsimprovementswheretheworkerwasaskedbythesupervisortoperformtheinstructionsoftheworkstudyperson.
2.Theworkstudypersonmustneverexpressopinionstoaworkerwhichmaybeinterpretedascriticaltosupervisor.
3.Theworkstudypersonmustnotallowtheworkersto“playhimorher”againstthesupervisor.
4.Theworkstudypersonifpossibleshouldneverstartactivityaloneandshouldinformsupervisoraboutpurposeofthevisit,aswellshouldtakeintoconsiderationsallobservationsofthesupervisorconcerningstudiedelementofworkoroperation.
Theserulesareveryimportant.Theworkersattheshopfloorcanhaveonlyoneboss–theirsupervisor–andeverythingmustbedonetosustainhisorherauthority.
Workstudyperson–worker:
Itisimportantthattheworkstudypersonisopenandfrankwithpurposeofthestudy.Workstudyhasnothingtohide.Theworkstudypersonmustmakeitclearthatnotworkeristheobjectofstudybuttheworkinitself.
Involvingtheworkersinthedevelopmentofanimprovedmethodofoperationcanconvincethemtothenewmethodandcanbringunexpectedresults.Askingaworkertherightquestionsandtakingintoconsiderationhisorherexplanationsorproposalsworkstudypersoncangetideasthathadneveroccurredtohimbefore,becauseworkerhasknowledgeofhisownjobandofdetailsthatcanescapeaworkstudyperson.
Takingintoaccountworkstudypersonitisveryimportantthatheorsheisreallykeenonthejob,believeintheimportanceofwhatisdoingandisabletotransmitenthusiasmtothepeoplearoundhim.
Movementsattheworkplace
Whenwecometostudyworkersattheworkplacethewayinwhichtheyapplytheireffortandtheamountoffatigueresultingfromtheirwayofworkingbecomeprimaryfactorsaffectingtheirefficiencyandproductivity.
Beforestartingdetailedstudyofaworkatasingleworkplace,itisimportanttomakecertainthatjobisinfactnecessaryandisdoneasitshouldbe.Thequestioningtechniquemustbeapplied:
1.PURPOSE(toensurethatthejobisnecessary).
2.PLACE(toensurethatisdonewhereitshouldbedone).
3.SEQUENCE(toensurethatitisinitsrightplaceinthesequenceofoperations).
4.PERSON(toensurethatitisdonebytherightperson).
5.MEANS(bywhichthejobisdoneandtosimplifythemasmuchasiseconomicallyjustified).
Theprinciplesofmotioneconomy
Thereareseveralrulesconcerningtheeconomyofmovementswhichhavebeendevelopedasaresultofexperienceandwhichformagoodbasicforthedevelopmentofimprovedmethodsattheworkplace.Theycanbedividedunderthreemaingroups:
1.Useofthehumanbody.
2.Arrangementoftheworkplace.
3.Designoftoolsandequipment.
Inshort:
Ad.1Useofthehumanbody
Whenpossible:
1.Thetwohandsshouldbeginandcompletetheirmovementsatthesametime.
2.Thetwohandsshouldnotbeidleatthesametimeexceptduringperiodsofrest.
3.Motionsofthearmsshouldbesymmetricalandinoppositedirectionsandshouldbemadesimultaneously.
4.Handandbodymotionsshouldbemadeatthelowestclassificationatwhichitispossibletodotheworksatisfactorily.
Classificationofmovements
Class
Pivot
Bodypartsmoved
1
Knuckle
Finger
2
Wrist
Handandfingers
3
Elbow
Forearm,handandfingers
4
Shoulder
Upperarm,forearm,handandfingers
5
Trunk
Torso,upperarm,forearm,handandfingers
Source:
GeorgeKanawaty,IntroductiontoWorkStudy,4THED.P.143
Itisobviousthateachmovementaboveclass1willinvolvemovementsofallclassesbelowit.Thusthesavingineffortresultingfromusingthelowestclasspossibleisobvious.Ifduringpreparationoftheworkplace,everythingneededisplacedwithineasyreach,thiswillminimizetheclassofmovementwhichtheworkitselfrequiresfromtheoperator.
5.Momentumshouldbeemployedtohelptheworker,butshouldbereducedtoaminimumwheneverithastobeovercomebymusculareffort.
6.Continuouscurvedmovementsaretobepreferredtostraight-linemotionsinvolvingsuddenandsharpchangesindirection.
7.“Ballistic”movementsarefaster,easierandmoreaccuratethanrestrictedorcontrolledmovements.
8.Rhythmisessentialtothesmoothandautomaticperformanceofarepetitiveoperation.Thework
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