Method Study
Flowcharting
Company
LOGO
Outline
1. Work Study
2. Method Study
3. Various Charts
March 23, 2016
Lab # 6: Method Study
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Work Study
 Work Study is a generic term for management services
and system engineering techniques, used to investigate:

Methods of performing work (Method Study).

The time taken to do it (Work Measurement).
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Work Study (Cont.)
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Method Study
 Method study is a technique to reduce the work content
mainly by eliminating unnecessary movements by
workers, materials, or equipments.
 However, even after that, there could be substantial
unnecessary time taken for the process because of lack of
management control or inaction of worker.
 Method Study approaches and tools of Method Analyst:
 Flow Diagrams & Process Charts etc.
 Critical questioning techniques.
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Method Study
 Method study is the systematic recording and critical
examination of existing and proposed ways of doing work,
as a means of developing and applying easier and more
effective methods and reducing costs.
 Used to analyze
 Movement of body, people, or material
 Activities of people & machines
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Method Study Objectives
 Improvement of processes and procedures.
 Improvement in the design of plant and equipment.
 Improvement of layout.
 Improvement in the use of men, materials and machines.
 Economy in human effort and reduction of unnecessary
fatigue.
 Development of better working environment.
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Method study - Methodology
 Procedure to accomplish method study, called "SREDIM"
shall be as follow:
1. Select: the job or operation that needs improvement,
2. Record: all facts, how work is done by chart methods,
3. Examine: every aspect of the job by asking; what, why,
where, when, who and how
4. Develop: review ideas, eliminate, simplify, combine,
re-arrange, make new method which more safe, chart
new method, submit for approval,
5. Install: the new method, consider best time to
introduce, convince all, train users,
6. Maintain: check frequently, match results, correct
deviations.
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Methodology (Cont.)
Select
Record
Examine
OK
?
Develop
Install
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Maintain
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Method Study Tools
 Exploratory Tools



Pareto Analysis
Fish & Bone Diagrams
Gantt and PERT charts
 Recording and Analysis Tools






Operation Process Chart
Flow process chart
Flow diagram
Worker and Machine Process Charts
Gang Process charts
Synchronous Servicing
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Method Study Applications
 The need for methods analysis can
from a number of different sources :
 Changes in tools and equipment.
 Changes in product design or new products.
 Changes in materials or procedures
 Other factors (e.g. accidents, quality problems)
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Recording Techniques
 Charts
1. Outline process chart.
2. Flow process chart (man-type, material-type and
equipment-type): This is the use of symbols and
description to chart the sequence of work. The process,
then, show what
is happening at different stages.
The distances and time may be given.
3. Two hands process charts.
4. Multiple activity charts: This technique is used to solve
problems where a number of items are dependent on each
other. The aim is to reduce idle times by using the
optimum number of each item. It depicts the occupied
times-broken down into the number of different activities
and the idle times both for the original and proposed
methods of doing the job.
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Recording Techniques
(Cont.)
 Diagrams and models (2-D and/or 3-D)
1. Flow diagrams, which is the use of symbols for flow
process charts, superimposed on drawings and the
"descriptions" are not necessary.
2. String diagrams, which is used for solving movement
problems since it shows congestions and excessive
distances.
3. Cut-out templates (2-D models).
4. 3-D models.
 Photography
1. Photographs,
2. Films,
3. Video.
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Assembly Chart
It is an analog model of the assembly process.
Circles with a single link denote basic components,
circles with several links denote assembly
operations/subassemblies, and squares represent
inspection operations.
The easiest method to constructing an assembly
chart is to begin with the original product and to
trace the product disassembly back to its basic
components.
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Assembly Chart (Cont.)
Assembly Chart for producing
Cheese Hamburger
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Assembly Chart (Cont.)
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Operation Process Chart
The operation process chart shows the
chronological sequence of all operations,
inspections, time allowances, and materials used
in a manufacturing or business process, from the
arrival of raw material to the packaging of the
finished product.
The chart depicts the entrance of all components
and subassemblies to the main assembly.
Two symbols are used in constructing the
operation process Chart : an operation and an
inspection.
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Operation Process Chart (Cont.)
Operations charts show the introduction of raw
materials at the top of the chart on a horizontal
line.
Operation
Number
Pieces / Hr
Hours / 1000
Some parts require no fabrication steps. These
parts are called buyouts. Buyouts are introduced
above the operation
Tape
Carton
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Operations Chart Steps
Step by Step Procedures For Preparing
Operations Chart:
an
 Identify the parts to be manufactured and purchased
 Determine the operations required to fabricate each part
and sequence them
 Determine the sequence or assembly for buyouts and
fabricated parts
 Draw the operations chart as explained
 Put time standards, operation numbers and descriptions
 Calculate and write down the total hours required per
1,000 units
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Operation Process Chart
Operation Process Chart for
Refrigerator Support
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Operation Process Chart
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Flow Diagrams
 A flow diagram is essentially a flow process chart drawn
to:
1. Show the layout of a facility.
2. Show the flow of work through that area
3. Show overcrowding areas, crossing worker paths, total
travel.
4. Identify how layout can be redesigned to reduce travel,
motion, collisions, etc.
5. Store materials near where they are used.
6. Increase efficiency and safety.
 Usually, the objective is to look for spatial relationships.
 It depicts the probable movement of materials in the floor
plant. The movement is represented by a line in the plant
drawing.
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Flow Diagram (Cont.)
Buyer
75 ft.
You
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Flow Diagram (Cont.)
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Flow Process Charts
A flow process chart is a chart of all the activities
involved in a process.
It is similar to an operations process chart, except
that more detail is shown by including
transportations and delays as well as operations,
inspections, and storages.
Not usually used for entire assemblies, it is used
for just one component (or operator)
Add in information on:
 Operation duration (time to complete)
 Distance traveled (for transport operations)
Good for showing savings of a new method.
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Flow Process Charts (Cont.)
Process charts summarizes the whole process
They are used to compare the existing and the
proposed methods
Process is observed, who, what, where, when, and
how questions are asked
Every detail is understood and the chart of the
existing situation is drawn
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Flow Process Charts (Cont.)
Quantity:
 Operations: Pieces per hour
 Transportation: How many are moved at a
time
 Inspection: How many pieces per hour if under
time standard and/or frequency of inspection
 Delays: How many pieces in a container
 Storage: How many pieces per storage unit
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Flow Process Charts (Cont.)
Time in Hours per Unit
 If 250 pieces are processed in an hour then 1
unit is processed in 0.00400 hours. Record 400
 If 200 units are moved in 1 minute, then 1/200
= 0.005 minutes per part, and 0.005/60
hours/part =0.00008 hrs/part. Record 8.
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Flow Process Types:
 Product or Material type
 Worker (Man) type
 Machine type
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ASME Standard Symbols
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Flow Process Chart Symbols
Operation
Delay
Transportation
Storage
Inspection
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Operation
Occurs when an object is intentionally changed in
one or more of its characteristics
Usually occurs at a machine or a work station
Drilling, Painting, Data Entry, Cutting, Sorting, etc.
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Transportation
Occurs when an object is moved from one place to
another
except when the movement is part of an operation
or an inspection
Using elevator, carrying, moving with material
handling devices
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Inspection
Occurs
when
an
object
is
examined
for
identification or is compared with a standard as to
quantify or quality
Examine the quantity or quality, read steam gauge
on boiler, detect the defectives
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Delay
Occurs when the immediate performance or the
next planned action does not take place
Work In Process inventory waiting to be
processed, Employee waiting for an elevator,
Waiting for accumulation of a certain quantity for
packaging
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Storage
Occurs when an object is kept under control such
that its withdrawal requires authorization
Bulk storage of raw material, finished products
inventory, archived documents
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Combined Symbols
Two symbols may be combined when two
activities are performed concurrently.
Operation and Inspection
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Flow Process Chart-An Example
Flow Process Chart Example
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Flow Process Chart-An Example
Process:
Subject:
Beginning:
Ending:
Emergency room admission
Ankle injury patient
Enter emergency room
Leave hospital
Insert Step
Append Step
Remove Step
Step
no.
Time
(min)
1
2
3
4
5
0.50
10.0
0.75
3.00
0.75
15
40
40
6
7
8
9
10
1.00
1.00
4.00
5.00
2.00
60
200
11
12
13
14
15
3.00
2.00
3.00
2.00
1.00
4.00
2.00
4.00
1.00
200
60
180
20
16
17
18
19
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Summary
Activity
Operation
Transport
Inspect
Delay
Store
Distance
Number
of steps
Time
(min)
Distance
(ft)
5
9
2
3
—
23
11
8
8
—
—
815
—
—
—
Step description
(ft)
X
Enter emergency room, approach patient window
Sit down and fill out patient history
Nurse escorts patient to ER triage room
Nurse inspects injury
Return to waiting room
X
X
X
X
X
X
Wait for available bed
Go to ER bed
Wait for doctor
Doctor inspects injury and questions patient
Nurse takes patient to radiology
X
Technician x-rays patient
Return to bed in ER
Wait for doctor to return
Doctor provides diagnosis and advice
Return to emergency entrance area
X
X
X
X
X
X
X
X
X
X
X
Check out
Walk to pharmacy
Pick up prescription
Leave the building
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Material Type - Example
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Man Type - Example
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Left-Hand-Right-Hand Charts
Useful in analyzing the work performed by one
person at one specific workstation. As the name
implies, the chart follows the motion of the left
and right hands of one operator .
Each hand of the worker is treated as an activity.
Each hand’s activities are broken into work
elements and plotted side by side on a time scale.
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Left-Hand-Right-Hand Charts (Cont.)
Lists the work performed simultaneously by
each hand


To assist in finding a better method of
performing the task and
To train the operator in the preferred method.
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Symbols
Two symbols are used in this chart:


Transportation (either an arrow or a small
circle)
Action (e.g., grasp, position, use, release)
A sketch of the workplace is drawn, indicating the
contents of the bins and the location of tools and
materials.


Record the motions of one hand at a time
Usually necessary to redraw the chart
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Left-Hand-Right-Hand Chart (An Example)
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L-R Hand Chart of Signing a Letter
LEFT HAND
RIGHT HAND
Reach for pen
Grasp pen
Carry pen to
paper
Hold Letter
Sign letter
Return pen to
holder
Release pen in
holder
Move hand back
to letter
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LEFT HAND
RIGHT HAND
Reach for
bolt in bin 1
Grasp bolt
Carry bolt to
work area
Position bolt
Reach for nut
in bin 2
Grasp nut
Carry nut to
work area
Position nut
Hold Bolt
Carry
assembly to
bin 3
Assemble nut
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Release nut
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Man-machine chart
 The worker and machine process chart (Man-machine
chart) is used to study, analyze, and improve one
workstation at a time.
 The chart shows the exact time relationship between the
working cycle of the person and operating cycle of the
machine.
 These facts can lead to utilization of both worker and
machine time, and a better balance of the work cycle.
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Worker-Machine Chart for a Gourmet Coffee Store
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Worker-Machine Chart for a Gourmet Coffee Store
The customer, the clerk, and the coffee grinder (machine) are involved in this
operation. It required 1 minute and 10 seconds for the customer to purchase a
pound of coffee in this particular store. During this time the customer spent 22
seconds, or 31 percent of the time, giving the clerk his order, receiving the ground
coffee, and paying the clerk for it. He was idle during the remaining 69 percent of
the time. The clerk worked 49 seconds, or 70 percent of the time, and was idle 21
seconds, or 30 percent of the time. The coffee grinder was in operation 21
seconds, or 30 percent of the time, and was idle 70 percent of the time.
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Multiple Activity Charts
Also known as Gang Process Charts
 Used when several workers operate a single
machine or render a single service
 Used when a single worker is operating several
machines
 Used to show the exact relationship between idle
and operating times of both workers and
machines
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Multiple Activity Charts (Cont.)
An operation performed by one member of the
group may continue while another member is
performing more than one operation.
The chart should cover the complete cycle for the
longest performing member.
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Activity Chart
Subject:
Time
1
2
3
4
5
6
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Semi-Auto Machine
Present
Operator
Machine
Load machine
Being loaded
Run
Idle
Unload
Being Unloaded
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Activity Chart for Two-Person
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Activity Chart of Emergency Tracheotomy
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Any Question
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