UNIT 6 WORK STUDY - AN OVERVIEW
Structure
6.1
Introduction
Objectives
History
6.2.1
6.2.2
6.2.3
6.2.4
F W. Taylor - The Scientific Management
Evolution of Tiine Study
Resistance to Time Study
Gilbreth's Contribution
6.2.5 Some More Contributions to Work Study
Scope and Objectives of Work Study
Work Study - An Overview
6.4.1 Time Study
6.4.2 Method Study
Definition of Work Study
Need for Work Study
Advantages of Work Study
Productivity and Work Study
6.8.1 Concept of Productivity
6.8.2 Production and Productivity
6.8.3 Role of Work Study
Productivity of Major Resources
Reasons for Low Productivity
Work Study - A Tool to Increase Productivity
Steps to Increase Productivity through Work Study
6.13 Summary
6.14 Key Words
6.15 Answers to SAQs
6.1 INTRODUCTION
Suppose there is a tough question and an easy question in your examination out of which
you have to answer one. Which one do you prefer to answer? Obvious answer is the
latter one. Why? Well, the answer could be the ease of answering or reduced risk or any
other advantage, which you sought. Suppose you have got a direct bus, which takes you
to your destiny in one hour and you can also go with a break journey by taking two
buses, which may take 2 hours. Obviously you will choose the former one unless you
have some work to do In between or if you do not get any seat or not attain any desired
advantage. Of course, this nature and tendency of human beings such as 'getting a work
done easily or fast or get more profit or benefit by putting less efforts' is not new.
Exactly, this tendency has necessitated the man to find new ways or discoveries or
inventions, which led him to get the present day's comforts and ease. The way that he
got is only by studying the methods and exploring the ways to improve the result in ease
or economy or fast. Work study is nothing different from this way of thinking to get a
better way of working.
7
Work System Design
Objectives
After studying this unit, you should be able to
understand what is work study,
know the history of work study,
think and explore the ways to make your job easy or'have time be
productive,
differentiate the production and productivity, and
explain how to improve productivity through work study.
6.2 HISTORY
The origin of work study is as old as the existence of the human beings. Perhaps the
basic objective of the human beings is to get the work done in better or easier way and
this is the core concept of work study.
As early as 18th century the Industrial Revolution had started particularly in British
Cotton Textile Industry. Many machines had been invented and improved. Sir Richard
Arkwright (1732-1792) was one of the most outstanding Engineers during this period,
who displayed excellent managerial qualities and probably the first man to realize the
value of training the workmen so that they eliminate the wastage of time and maintain
systematic work habits.
J. R. Perronet, a Frenchman in 1760 made some efforts in systematic overall time study
on manufacturing of pins and arrived at a standard production rate. His contemporary,
Matthew Boulten, who started a factory at Soho in 1762, had encouraged mechanical
inventions, which were superior in multitude variety and simplicity. Most important of
all, he had llighly trained and skilled craftsmen who were more accurate than others in
hardware trade of English midlands at that time. Within the span of 4 years (between
1963-1967) his turnover increased to $30.000 from $3,000.
A Britisher, who contributed in this field, was Robert Owen (1771-1858), who may be
conceded as a precursor of method study and the first man who thought about the rest
allowances for compensating fatigue jobs, considering the human element of labour.
Charles Babbage (1792-1891), who devoted most of his time in developing a calculating
machine, was not an engineer or practical industrialist but was in the forefront of the
movement of scientific inquiry.
All though the initialization of work study could be attributed to Europe, the modern
ideas on work study were developed by American Engineers.
6.2.1 F. W. Taylor - Scientific Management
Frederick Winslow Taylor (1856-1915) is considered as the father of Modern Industrial
Engineering and he did much pioneering Work in the field of work study. His effort and
ideas in 'Scientific Management and work Measurement' in Industrial Engineering came
into existence in USA in 1881. He concentrated his activities in the area of maximum
production in minimum time and developed a formula. It has three elements :
(a)
A definite task
:
The best and correct sequecce of operaticn
(b)
A definite time
:
By stopwatch or from standard data
(c)
A definite method :
Developed by a detailed experimentation.
Taylor developed and proved the technique of management called as the task system. He
tried to eliminate the brutalisation of men, started in Industrial Revolution. Due to
scientific management and technical advances a new impersonal relation came about
between employers and workmen.
Taylor observed cause of conflicts is that management, without knowing what is proper
day's work, tried to secure maximum output by pressure. He made a clear conclusion that
management would gain by elimination of waste of workers' time and machine time,
more than that by pressurizing them.
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6.2.2 Evolution of Time Study
In support of the conclusions, Taylor established a technique of time study and
demonstrated scientifically. He brokedown the cycle of the operation of a job into small
group of inotion called elements.
Each element was separately tiined to facilitate the analysis, which made possible to
recognize, isolate and eliminate or prevent the loss in efficiency.
6.2.3 Resistance to Time Study
Taylor task system was introduced in many factories by efficiency experts, but the
unfortunate thing was that they were not equipped to handle problem of human relations.
With insufficient knowledge of the system, they imposed timings for completion ofjobs,
which were difficult to accomplish, it faced strong opposition from the labour. This
disturbance spread to such an extent that lnterstate Commerce Commission in 1910
started an investigation on time study, whose findings were against the time study. This
resulted in imposing ban on time study in 1913 'oy the US Government. However, at the
hearings of special community Taylor's testimony showed a great humanitarianism and
understanding of the need of labour.
6.2.4 Gilbreth's Contribution
Taylor's primary objective was determining the time required for a job and had paid a
little attention to the possibility of improving the method. The credit of investigating the
possibilities of improving the method goes to Frank Gilbreth (1868-1924) and his wife
Lillian M. Gilbreth. Gilbreth was originally a bricklayer. He applied the principles of
scientific analysis and had shown a tremendous and immediate increase in the output per
man-hour. His three years analysis and study of art of brick laying enabled him to reduce
the number of motion by workmen in laying brick from 18 per brick to 5 per brick. As a
result of this, the most rapid union rate of brick laying (120 bricks/man/hour) had
increased nearly three folds (360 bricks/man/hour) on an average. Development of the
principles of motion economy, discovery of THERBLIG and use of micro motion
pictures for motion analysis are the memorable contributions of Gilbreth.
The spectacular result secured by combination of time study, motion study and wage
incentive plans tempted the industrialists during the early decades of 20th century.
During the period of 'First World War', when the demand for increased production
reached the peaks, the principles of work study were applied extensively. However,
during the period between the two world wars, a sound work study was installed by
qualified persons who demonstrated the advantages of work study.
Gilbreth presented a refinement in these original motion study techniques in the form of
motion pictures in 1912. Their techniques eventually developed and are now known as a
cyclographic and chrono cyclographic analysis,
6.2.5 Some More Contributors to Work Study
Though the major work was due to Taylor and Gilbreth few more names of contributions
should not be forgotten in the history of work study.
Allen H. Mogensen, Common Sense, applied to inotion and time study
(1932) emphasized the importance of work simplification.
Lowry, Maynard and Stegemerten : Time and Motion Study and Formula
for Wage Incentives, ( 1 930).
Maynard and Stegemerten, Operation Analysis, (1939).
WorkStudyAn Overview
Work System Design
a
Charles E. Bedaux in 191 1 conducted experiments on the idea of measuring
all human physical work, which gave a way for work measurement.
Henry L. Gantt (1 86 1- 1919) introduced the chart widely used as Gantt
Chart in work-study today.
F. A. Halsey, James Rowan, Emerson, Hayney, Priestman, Nunnbush were
some of the contributors on this line.
a
The work study has taken another branch as ergonomics due to C. T. Gould
and Dr. Franklin V. Taylor.
Ralph M. Barnes, Motion and Time Study, (1949) are a few to mention in
this context.
Activity 1
(a)
(b)
Work study was resisted by the workers, managers and the industrialists
too. Guess the reasons from each group.
(i)
Reasons for workers' resistance : .........................................................
(ii)
...............................................................................................................
Reasons for managers' resistance : .......................................................
(iii)
...............................................................................................................
Reasons for owners' resistance : ..........................................................
Imagine the situations of resistance and think of some unrest due to the
introduction of work study in an organisation. Write a one-act play with
four to five characters of various levels and do role playing.
SAQ 1
(a)
Give an account of evolution of work study.
(b)
What are the contributions of F. W. Taylor towards work study?
(c)
What are the Gilbreths' contributions towards work study?
6.3 SCOPE AND OBJECTIVES OF WORK STUDY
Though the work study is originally developed for improving the productivity and
efficiency of the production, the technique is applicable widely. Industrialists and
educationalists have recugnised its significance and have been applying in every field
even in transport offices, sales and distribution and many more service organisations.
Work study finds a place in every field for improvement of the method. Further it is
useful to any field and at any point of time anywhere for exhibiting the excellence.
Basic objectives of the work study are
(a)
Improvement in working process.
(b)
Standardisation of procedures.
(c)
Effective utilisation of resources like men, materials, machine, money and
time.
(d)
Efficient and fast material handling.
(e)
Decision on fair day wage.
(f)
Enabling a good decision making on manpower requirements, etc.
(g)
Better work culture, working environment by ergonomic studies.
(h)
To provide an effective control of system.
(i)
To make the method of doing operation easy.
(j)
To economise the movements i.e. motion economy.
(k)
To increase the productivity by eliminating the unnecessary work elements.
(1)
To make an effective layout of work place so as to reduce the number of
movements.
SAQ 2
What are the objectives of work study? Explain them.
6.4 WORK STUDY - AN OVERVIEW
Work study is the investigation, by means of consistent system to attain the best possible
use of available men, machine, materials, money and time. Total concept of the work
study is concentrated upon the answers of following two questions.
(a)
How should a job be done? How a job should be done?
(b)
How much time a job should take for completion?
The answer for the first question is method study while the answer of the second
question is time study and work measurement. In fact method study and the time study
are not to be treated as two different parts of the work study and are very much
inter-linked. However for the ease of understanding, the work study is often classified
into two parts as time study and method study as shown in Figure 6.1. Time study with
its extension is known as work measurement whereas method study is sub-divided into
Work Study An Overview
\Vork System Design
two groups as motion study and micro motion study. The motion study has extended to
the motion eaonomics while micro motion study has led a way to ergonomics.
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Tlme Study
~ethod
study
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Work Management
Motion Study
Study
F i g u h 6.1 :Classification of Work Study
6.4.1 Time Study
Time study is the brain child of F. W. Taylor, whose philosophy was mainly
concentrated to develop a scientific method to any human problem. This is attained by
selecting a worker for each particular task and then training him soundly, essentially by
developing cooperation between workers and the management. Of course, the division of
work, the responsibility, the authority and the accountability are the distinct features to
be observed in cultivating this work culture. Taylor's approach was further developed by
his students Barth and Merrick and is summarised as follows :
(a)
Split up a work into small activities called elemental movements or simply
elements.
(b)
Eliminate all unnecessary elements.
(c)
Assign time to each elemental motion accurately with the help of stop watch
or standards.
(d)
Classify and describe each elemental motion and its time carefully for
future reference.
(e)
Add an allowance to actual time to cover the time delays due to known or
forecasted or unforeseen reasons.
(f)
Standardise the tools and working conditions with more emphasis laid on
method improvement.
Taylor summarised all these in three simple words viz. Definite task, Definite time and
Definite method. His study was directed towards the specialisation and standardisation.
Time smdy has also given rise to a firm scientific and calculative opinion on
remuneration system.
The remuneration system as per time study sticks on to the following points :
(a)
Assign each worker a clearly defined task with definite time.
(b)
Provide each worker with such standard conditions and appliances as will
enable him to accomplish the task with certainty.
(c)
Remunerate each worker with large pay when he accomplishes his task.
(d)
Make sure that when a workman fails, he is the loser thereby.
Thus time study I S basically a work measurement technique and is defined as follows
(according to I. L. 0.).
Time study is a work measurement technique for recording the times and rate of
working for the elements of a specified job carried out under specified conditions
and for nnalysing the data so as to obtain defined level of the performance.
6.4.2 Method Study
Method study is a systematic and scientific evaluation of existing and proposed plans
and perfomlance of a work and evaluation of improvement through analytical process of
critical examination. This is a broad investigation for improvement of total department,
layout of machines, equipment, flow of materials and movement of men. This will be
discussed in Unit 7. Method study has two levels of its application. These are :
(a)
Motion study, and
(b)
Micro-motion study.
Motion Study
This is more detailed investigation of individual operation or operator and layout
of materials, parts or tools around a working bench or machine, use of jigs,
fixtures and consumables to perform the job effectively. The study of
environment, body postures, gestures, the noise level, the temperature, the
pressure, the humidity around the work place are the major concerns of motion
study which are now known as 'ergonomics'.
Micro-motion Study
This is the most detailed investigation of the movements of hands, arms, limbs,
legs, head, etc. while performing the job. Motion pictures, cameras, filmed
records, etc. are a few tools used to study the micro-motions of a specified job.
The pioneering developments of Frank Gilbreth and his wife Lillian Gilbreth through
process charts, Therbligs, cycle graphs, chrono-cycle graphs, etc. are ever new
techniques applied world-wide in micro motion study.
Industrial engineers believe that Method study stands on three pillars, namely the
Economic factors, Technical factors and Human factors. Why these factors are called as
the pillars? The answer for this question is not beyond the thinking of the reader. Yes, it
has to take care of these three factors in the equal proportions. Method study is
represented and defined as follows :
Method study is analysing
Economic factors
Technical factors
Humail factors for
Operation and
Development
The basic procedure of method study consists of the following steps :
(a)
Define the problem and select the work to be taken for the study.
(b)
Record all the relevant facts about present method.
(c)
Examine the facts critically and impartially.
(d)
Develop the most practical, economical and effective method which will
satisfy the three pillars viz. economical, technical and human factors.
(e)
Define the new and improved method so that the method can be identified
1
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Work System Design
Method study can be applied to layout, working conditions, movements, quality
standards, designs, tools and equipment and material handling which may be detected to
achieve the improvements either in short term or in long term benefits.
Thus method study is defined as follows (according to I. L.0.).
The systematic recording and critical examination of existing and proposed ways of
doing a work as a means of developing and applying easier and effective method
and thereby reducing the cost.
The readers may always get a doubt that out of method study and time study, which one
starts first? After understanding the two terms -time study and method study - this
question often confuses the readers since the work measurement (time study) is done for
a definite method and a definite task. But based on the time study an industrial engineer
can critically examine the effectiveness of the method. Because work measurement has
to be based on a standardised method it would be obviously absurd to standardise or to
find the best method.
The time taken for the job is important in method study and hence time study seldom
precedes while finding improved method. While for a new job the method study should
succeed the time study to standardise it. All the techniques of work study are in fact
inter-related and any separation is only for convenience of decision. It is as same as
questioning "Is seed first or the tree?' The discussion is endless in fillding the exact
answer. Hence the readers are once again clarified that method study and time study are
two different parts of work study.
Activity 2
Write some slogans on work study, method study, motion study and micro-motion
study and exhibit in your organisation.
SAQ 3
(a)
Write an essay on work study.
(b)
Define and explain the following :
(i)
Time Study
(ii)
Method Study
(iii)
Motion Study
(iv)
Micro-motion Study
6.5 DEFINITION OF WORK STUDY
Afier getting an overview of the work study you would have already arrived to clear cut
definition of work study. According to British Standard Institution (BSI) work study is
defined as follows :
"Work study is generic term for those techniques particzllarly method study and
work measurement, which are used in all its contexts and which leads
systematically to the investigation o f all the factors which affect the efficiency and
economy of situation being reviewed."
In simple words "It is a terin embraces the techniques of method study and work
measurement which are employed to ensure the better possible use of human and
material resources in carrying out a specific task." And in another way work study
can also be defined as "the systematic. objective, critical and imaginative
examination of all factors governing the operational efficiency of any specified
activity in order to effect improvement."
6.6 NEED FOR WORK STUDY
Many concepts have been developed in the recent past for improvement such as Value
Engineering, Waste Elimination, Kaizen, Zero Defects, etc. Yet, work study did not lose
its identity and has got its own charm and significant role in continuous improvement
plans of the job due to its specific characteristics and features. The strong base,
supportive experimentation and immediate results are making it ever new process.
Further it is uniting the people at all levels like owner, managers, foremen and workers
by clubbing the various resources like time, machine, material, men and method.
The work study is a wonderful tool, which can inter-link any two resources like time and
method, men and machine, man and material, etc. The industrialists and industrial
engineers have realised the effective working of work study and recognised ease in it. On
the other side, they are also identifying need for improving the productivity in the
competitive world with growing demand. To meet this demand there are only two
options - first is to increase the volume or capacity of production by enhancing their
machinery or equipment orland men orland material. The second option is to increase the
productivity and thereby its capacity by eliminating waste. The former method is costly
and cumbersome and involves decision making at many stages. Particularly it is mostly
advisable to capital intensive industries. While the latter one is applicable to all the
sectors and to all the situations as it is easy and less expensive.
Hence, the managers prefer to conduct the work study on their jobs. Since globalisation
is demanding the standardisation and liberalisation in extending the competitive spirit,
the present world has understood the need for work study on every elemental movement
of operation of their work or task.
Summarily, we can say that work study will be needful to the organisation as shown in
Figure 6.2, it takes care o f :
Figure 6.2 : Different Aspects of Work Study
Economic Aspects
Such as cost reduction, increased production, variety of products in monetary
terms.
Work Study A n Oven'iew
Work System Design
Technical Aspects
Such as improvement in process, method refinement, elimination of waste
elements or movements, technology upgradation, standardisation, product
compactness, equipment renovation, product development, etc.
Human Aspects
For example, ease of operation, comfort to producer, customer or user, safety to
human beings, machinery and environment.
SAQ 4
(a)
Define work study. Explain its need in Indian industrial scenario.
(b)
Give the basic aspects that a work study takes care of.
6.7 ADVANTAGES OF WORK STUDY
Work study has numerous advantages. The merits which have gained the prominence are
listed below.
Cost Reduction
The sltudy results in lowering of cost of manufacturing as it eliminates unnecessary
movements in work or job or motions.
Productivity Improvement
It enhances the efficiency of the production and hence increases the productivity.
Profitability
It raises the profitability without rais'ing the sales price of the product. For
example, a product manufactured at Rs. 100 and sold at Rs. 120 will give a profit
of Rs. 20, which is 20%. If the same is able to be manufactured at Rs. 80 by using
work study and is sold at Rs. I00 gives a profit of Rs. 20 but it is 25%. And if it
sold at Rs. 120 imagine the profitability, which is about 50%. This is definitely
better than raising the sales price to Rs. 150 (to get a profit of 50%) and making
uncertain or risky sale ability, which takes the product away from the common
customer's reach.
Standardisation
The work study standardises the work by which the employees get job security
and the customer finds reliability and interchangeability. The target or task
performance of the worker will be his weapon to safeguard his job while
customers get delighted by getting a standard product.
Easier Work
The purpose of the work study is fulfilled if the job is made easier even though it
couldn't reduce the cost nor increase the production. Because the ease in doing the
job will automatically raise the productivity by reducing the fatigue in the
employee.
Fair Day Wage
As the work is timed and based on this, the target is fixed, the operator gets a "fair
day wage" as explained in Taylor's approach. This not only regulates the
employee but also provides the employer a good control over the workmen. So
also it builds up a fair relationship between the employer and employee.
Bctter Working Conditions
Work study provides good working conditions by which the worker would love to
work in the environment. It also makes the work place clean. neat and tidy and
thus brings out a good working culture.
Deterministic Production Schedules
The work study proves the job to be practicable and hence results in exactness in
the production by which the production schedule can be met as per the plan. This
makes the producer to satisfy the customer by meeting the delivery schedules
accurately.
Activity 3
List out the areas in your organisation (or the organisation with which you are
most familiar), where conducting the work study is needed. Also give reasons why
you feel that there is a need.
SAQ 5
(a)
Enumerate the advantages of work study.
(b)
"Work study is powerful tool for management while it is a boon for
workers." Critically appreciate the statement.
6.8 PRODUCTIVITY AND WORK STUDY
In any country, the satisfactory living standard depends on national productivity. The
degree of availability of different matters like food, clothing, shelter, security and
essential services to the country depends on the productivity in a macro level but when
seen in a micro level, a productivity of each of the above things is a challenging task to
the country. As the summation of all these micro development builds up the macro level
development, the responsibility of developing the productivity at micro level has come
on to shoulders of every citizen in general and industrial engineers in particular. This
necessitates the industrial engineers to understand the concept of productivity and how
best it could be improved through the work study.
6.8.1 Concept of Productivity
The term productivity has been used for the first time in 1776 by Dr. Quensney, a great
physiocrat but after so many years, i.e. at the end of 19th century it was understood as
the factor to produce.
Drucker defined productivity as "The balance between all factors of production that will
give the maximum output for the slnallest effort."
Some More Definitions
Productivity in its broadest sense is the quantitative relationship between what is
produced and the resources, which are used.
Productivity may be defined as the ratio between the output and input.
\\'ark Study An Overview
W o r k System Design
The concept ofproductivity has been termed in variozis ways such as attitude of
mind; continuous efforts towards progress; the certainry of being able to do better
tomorrow than today. Some people called the productivity as the personal
efJiciency and to some others the output of an aggregate collection of resources.
Mathematically, the productivity can be represented as the ratio of output to input.
Productivity (P) =
Output of the system ( 0 )
Input to the system (I)
6.8.2 Production and Productivity
These terms have already been explained in Unit 5, and are refreshed here to facilitate a
quick reference.
We know that the production or the output being the result of coordinated effort and the
productivity (efficiency) is the function of efficiencies of all the specialised units whose
coordinated efforts lead to production. Hence, it is clear that the productivity (P) of a
system is the function of efficiencies of many subsystems (P,).
Productivity (P) = f (P,)
All the subsystems together lead to productivity of the whole system.
So production is the conversion process of the raw materials into useful products or
items by using human efforts and time, materials and machinery in easier, economic and
safer methods in a minimum possible time.
Increase in productivity is the contemporary of increase in output, also increase in input
or resources. It may be likely that the increase in output causes the productivity to
remain constant, decrease or increase. It depends upon mainly the effective utilisation of
resources like materials, machines, methods, men. etc. so as to achieve the maximum
productivity, where the work study plays a key role.
6.8.3 Role of Work Study
As explained above, Productivity of a system is the function of production, all individual
subsystems and production depends on the output and input characteristics. The
increased output results in more production, but it need not be high productivity. The
increase in productivity is resulted by one of the following ways :
(a)
Output is increased when input is constant.
(b)
Same output or result is attained by reducing input (eliminating the waste).
(c)
Output is raised while input or resources are reduced (eliminate waste).
Work study shows the way to achieve the above so as to increase the productivity
because it basically aims in :
(a)
Increasing output.
(b)
Doing the work faster.
(c)
Easing the work and hence enabling the workman to work more.
(d)
Eliminating waste elements of motions and time.
Thus the work study plays a vital role in achieving the high productivity.
SAQ 6
Define the terms : production and productivity. Distinguish between them.
How is work study related to productivity? Establish the relation.
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6.9 PRODUCTIVITY OF MAJOR RESOURCES
Productivity of Land
: This means revolution in cultivation to increase
the yield per unit land by using better seeds, better
cultivation techniques and better and proper
utilisation of fertilizers and pesticides.
Productivity of Machines
: This means the effective utilisation of mach~ne
hours for maxi mu^^ output, using appropriate
cutting tools and improved cutting parameters like
speeds, feeds, depth of cuts, etc. This is possible
by using well designed machine tools, improved
working methods to cany out different operations.
In this area work study plays important role to
improve the methods and efficiency of machine
through time study.
Productivity of Men
: It is the increase in production rate through better
and improved methods. Training of the workman
in improving his skills, efficiency, quality of
output, interest on job make him to handle in
quicker time.
Productivity of Materials
: It is making an item by the raw material with
ininimum waste through proper planning, design
and better machining methods. If you reduce the
wastage of material in process, the output may
increase per unit input of raw materials.
6.10 REASONS FOR LOW PRODUCTIVITY
Before the industrial revolution, there are no proper methods and time sense to complete
a job or task. But with passing time man started putting more emphasis on the main
factors, which constitute work study. At present he is inclined to productivity and tried
to reveal on the reasons for low productivity. In his investigation the following reasons
were observed.
(a)
In employee point of view, the major areas are :
(i)
Abilities and job interest
(ii)
Skills and efforts
(iii)
Human needs like food, health, shelter, education, etc.
(b)
The working conditions like bad or insufficient light, heat factor, poor
ventilation, no safety and risk coverage in case of any mishap.
(c)
Poor technology in the form of improper design of products, plant layout,
no standard methods, non-availability of right materials for cutting tools,
etc.
(d)
Organisational factors like
improper plant layout and machinery
no safety measures and equipment
lack of motivation and influence of trade unions and improper wage
policies
frequent accidents.
Work Study An Overview
\\ark System Design
6.11 WORK STUDY - A TOOL TO INCREASE
PRODUCTIVITY
Amongst all the techniques available to the management to counteract the reasons for
low productivity, work study stands forefront because (a)
By direct means it rises the productivity of any organisation with minimum
investment.
(b)
Most accurate technique to set the standards of performance.
(c)
Anywhere it can be applied successfully.
(d)
Reduces the inefficiency of any organisation.
(e)
Doesn't overlook any factor affecting the productivity.
Beneficial to all categories in the organisation as given below
(a)
Profits to the management by increasing the productivity.
(b)
To give the concept of fair day work to the worker and reduces the
overload, fatigue and enables worker to make in easy and scientific way.
(c)
Provides reliable and consistent standards of performance and related data.
(d)
Consumer can always get the quality goods at low prices.
SAQ 7
(a)
List out the reasons for low productivity.
(b)
How can you counteract to situation of low productivity with the help of
work study?
6.12 $TEPS TO INCREASE PRODUCTIVITY
THROUGH WORK STUDY
The work study is used to improve process by research and development and providing
more improved physical means to motivate the workers. This automatically raises the
production as well as productivity. The following strategic aims or objectives are
normally adopted for improvement of plan through work study.
(a)
Standardisation of the product and process.
(b)
Improving operational methods and improving man-power efficiency at all
levels.
(c)
Strategic planning and effective utilisation of capital and resources.
(d)
Effective planning and implementation.
(e)
Updating the plans and making short term plans to improve the output out
of long term plans.
Now, the steps to improve the productivity through the work study go as follows :
(a)
Understand the type of production whether it is intermittent or continuous
or project type.
i
(b)
Understand the quality policy and other pre-set norms of the industry.
(c)
Calculate partial and total productivity indices for the existing level of
production.
(d)
Identify the areas where the productivity is very low.
(e)
Check whether it is worthwhile to conduct work study i n all angles like,
economic aspects, human aspects and technical aspects.
(9
Narrate all the facts that are available regarding the joblprocess.
(g)
Analyse the process to think whether any other method can save or ease the
movements of work.
(h)
Choose the best method that reduces risk and saves the movements and/or
eases the workman to perform the job and standardise it.
(i)
Split the job into small activities called elements to analyse and if any waste
elements of time can be found.
(j)
Eliminate the waste elements, if any, through conduction of time study and
sufficient experimentation in all combinations.
(k)
Analyse the working conditions.
(I)
Improve the working conditions ergonomically.
(m)
Standardise the time by defining each task, its method and their times.
(n)
(0)
Re-calculate the productivity indices and compare the results.
Install, l~nplementand Maintain.
Activity 4
Establish a relation between productivity and work study and represent it through
a flow-chart.
6.13 SUMMARY
Work is worship. Work study is to know the method of worship. Of course, most of the
jobs are already been studied, yet, there is large scope for employing work study in the
industrial jobs in the interest of improving the productivity ofthe industry. Particularly
in India the importance of work study is largely ignored by many industries. Though
some industries have realised. it is still insufficient. Perhaps, the reason is that the
industrialists could not understand fully about the advantages of work study or they are
not aware of methodology that how it is to be conducted. The globalisation and
liberalisation are posing challenges to the Indian industries and even questioning their
survival in some cases. In such cases, it is a high time to recall the concept of work study
to redefine their tasks. The companies started realising the reality and looking forward
for improving rheir productivity through various methods such as value engineering,
waste elimination. zero defects and just in time concepts. But, it should not be forgotten
\\'nrk Study An Overview
WurkSystem Design
that work study is supposed as mother for all these concepts to give a thought for their
generation. Even you thoroughly know, understand and learn any concept. it goes waste
if you do not put it into practice. And the work study is not an exception.
A broad picture about the work study is explained in this unit which is composed of
method study and time study. The time study, now-a-days called work measurement is
the systematic way of measuring the time required for performing a job. 'The correct and
technological sequence that reduces the number of motions and hence the cost, and also
makes the operation easier is decided by evaluation through the method study. The
method study is further divided as motion study and micro-motion study, which go into
greater details of the motions of work elements and eliminate the waste and unnecessary
elements. The contributions of F. W. Taylor, Scientific Management and Time Study and
F . Gilbreth, Method Study and Motion and Micro-Motron Studies, and others in this
regard are explained. The history of development of the work study has also found some
place in this unit. The production, productivity, efficiency, effectiveness, etc. are briefed
out and an effort is made to create the ideas of improving the productivity with the help
of work study.
6.14 KEY WORDS
r
Work Study
Work study is generic term for those techniques
particularly method study and work measurement,
which are used in all its contexts and which leads
systematically to the investigation of all the
factors which affect the efficiency and economy of
situation being reviewed.
Time Study
Time study is a work measurement technique for
recording the times and rate of working for the
elements of a specified job carried out under
specified conditions and for analysing the data so
as to obtain defined level of the performance.
Method Study
The systematic recording and critical examination
of existing and proposed ways of doing a work as
a means of developing and applying easier and
effective method and thereby reducing the cost.
This is a broad investigation for improvement of
total department, layout of machines, equipment,
flow of materials and movement of men.
Motion Study
This is more detailed investigation of individual
operation or operator and layout of materials, parts
or tools around a working bench or machine, use
of jigs, fixtures and consumables to perform the
job effectively.
Miqro Motion Study
This is the most detailed investigation of the
movements of hands. arms, limbs, legs, head, etc.
while performing the job. Motion pictures,
cameras, filmed records, etc. are a few tools used
to study the micro motions of a specified job.
Ergonomics
The study of environment, body postures,
gestures, the noise level, the temperature, the
pressure, the humidity around the work place are
the major concerns of method study which are
now known as 'ergonomics'.
Definite Task
: In F. W. Taylor's words, who used it first, it is the
specific and scientifically measurable well-defined
target of a job.
Definite Time
: According to F. W. Taylor, it is the standard time
(along with the allowances) required for
performing a job most economically.
Definite Method
: The correct sequence of performing a job, which
will reduce the cost and time of operation and can
make the operation easy. This word is first used
by F. W. Taylor.
Productivity
: Productivity may be defined as the ratio of output
to input.
6.15 ANSWERS TO SAOs
Refer the relevant preceding text in this unit for answers to SAQs.
Work Study An Overview