UNIT 2
WORK STUDY, INCENTIVES AND
SAFETY
Work study
It 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 activities being carried out.
Total work content = basic work content + work
content added due to poor product design or
improper utilization of the materials + work
content added by inefficient methods of
manufacture + ineffective time due to inefficient
human resources.
Why work study?
It improves the not just production but also
productivity
It is systematic
It is the most accurate method
It improves the safety and work conditions at
the work
It can be applied anywhere
Techniques of work study
1. Method study: It is the systematic recording
and critical examination of ways of doing
things in order to make improvements.
2. Work measurement: It is the application of
techniques designed to establish the time for
a qualified worker to carry out a task at a
defined rate of working.
Method study
The basic steps of method study are:
1. SELECT
2. RECORD
3. EXAMINE
4. DEVELOP
5. EVALUATE
6. DEFINE
7. INSTALL
8. MAINTAIN
Charts and diagrams
Charts and diagram are used to record the activities.
Commonly used charts are
1. Outline process chart
2. Flow process chart – material type, men type, equipment
type
3. Two handed process chart
4. Multiple activity chart
5. Simo chart
Commonly used diagrams are
1. Flow diagram
2. String diagram
3. Cycle graphs
4. Chrono cyclegraphs
5. Travel chart
Process chart symbols
1. Operation
2. Inspection
3. Transport
4. Delay or temporary storage
5. Permanent storage
Principles of motion economy
These principles are concerned with economy of
movements that are developed over years of
experience, which can be grouped into three
categories
1. Use of human body
2. Arrangement of the workplace
3. Design of tools and equipments
Use of human body
1. Two hands should begin and complete their
movements at the same time
2. Two hands should not be idle at the same time except
during period of rest
3. Motions of arms should be symmetrical and in opposite
directions and should be made simultaneously
4. Rhythm is essential for the smooth and automatic
performance of a repetitive operation
5. Work should be arranged so that the eye movements
are confined to a comfortable area.
6. Free swinging movements are faster, accurate and
easier than restricted movements
Arrangement of the workplace
1. Definite and fixed stations must be provided
2. Tools and materials must be pre positioned to reduce
searching
3. Gravity feed, bins and containers should be used to
deliver the materials
4. Tools, materials and controls should be located within
the maximum working area
5. Drop deliveries and ejector pins must be used
wherever possible
6. Color of the workplace must be contrast with that of
the work
Design of tools and equipments
1. The hands should be relieved of all work of
‘holding’ the work piece
2. Two or more tools must be combined wherever
possible
3. The load should be evenly distributed in
accordance with inherent capabilities Ex:
Typewriter
4. Handles of the tools must be so designed as to
make maximum surface of the hand is in contact
with the handle
Work measurements
The basic procedure is:
SELECT
RECORD
EXAMINE
MEASURE
COMPILE
DEFINE
Standard time
It is the total time in which a job should be
completed at standard performance
Standard performance is the rate of output which
qualified worker will naturally achieve without
over-exertion as an average over the working day
or shift, provided that they know and adhere to
the specified method and provided that they are
motivated to apply themselves to their work. This
is regarded as 100% on performance scales.
Qualified worker is the one who has acquired the
skill, knowledge and other attributes to carry out
the work in hand to satisfactory standards of
quantity, quality and safety.
Standard time
Standard time = basic time + allowances
BT= Observed time X observed rating/standard
rating
Rating is the assessment of workers rate of working
relative to the observers concept of the rate
corresponding to the standard pace.
Job evaluation
Job evaluation systems are developed to fix the
salary.
The following principles have to be used
1. Rate the job not man
2. Select minimum elements but cover all job
requirements
3. The rating plan must be easily understandable
4. Foreman or supervisors must be involved.
5. Employees must be allowed to participate
Types of job evaluation
1. Ranking method – involves responsibility,
amount of work, difficulty, supervision required
2. Classification method – graded based on equal
levels of skill difficulty and responsibility
3. Factor comparison – mental requirement,
physical requirement, skill requirement,
responsibility, working conditions.
4. Point rating – job factors will be subdivided into
sub factors, each sub factor will be given
weightage Ex: Skill – education, experience,
initiative.
Incentive plans
1. Piece rate system
2. Cent per Cent premium – any early completion
of the job will attract more salary
3. Halsey premium plan – daily wage is fixed, in
addition the extra wage is give at the rate of
33.33% of the basic W=R*T + (P/100)*(S-T)*R
4. Bedaux premium plan – here the extra wage
rate is 75%, W=R*T+(Ns-Nt/60)*0.75*R
5. Rowan premium plan – W=R*T + (S-T/S)*R*T
Training and development
Objectives:
1. Increase productivity
2. Make employees more effective
3. To bring more cordial relationship
4. To increase the morale
5. To increase the co-operation
6. To develop the individual
7. To increase the knowledge
Training methods
1.
2.
3.
4.
5.
6.
7.
on the job training
Training center training
Demonstration
Apprenticeship
Programmed instruction
Films/slides
Simulation exercises
Industrial safety
Due to unsafe working conditions two types of
losses occur
1. Direct losses – which can be compensated
2. Indirect losses – time of worker, decrease in
morale, loss to machine, reduction in
efficiency, etc.
Reasons for accidents
1.
2.
3.
4.
5.
6.
7.
8.
Age
Experience
Improper layout of machines
Moving objects
Unsafe working conditions
Electrical causes
Personal reasons
Exposure to harmful substances
Preventive measures
1.
2.
3.
4.
Safe workplace and working conditions
Safe material handling
Personal protection devices
Good housekeeping