Lehrstuhl und Institut für Arbeitswissenschaft der RWTH Aachen Industrial Engineering, Ergonomics & Work Organisation Unit 4 Work and Time Study I winter term 2005/2006 Univ.-Prof. Dr.-Ing. Christopher Schlick Structure: Work and Time Study 1 Work and Time Study - Basics 2 REFA - Stop Watch Time Study 3 Work Sampling method 4 MTM method 5 MTM method - Case Study 6 Conclusion © IAW 2005/2006 Work and Time Study I Work and Time Study II 2 Learning Targets Work and Time Study I Being acquainted with the operational purpose of time data Being capable to distinguish between different REFA types of activities and different REFA types of times Being capable to distinguish between different methods for the determination of time data Understanding the REFA Stop Watch Time Study method and the work sampling method Being acquainted with possibilities and limitations in the usage of these time measurement methods © IAW 2005/2006 3 Structure: Work and Time Study 1 Work and Time Study - Basics 2 REFA - Stop Watch Time Study 3 Work Sampling method 4 MTM method 5 MTM method - Case Study 6 Conclusion © IAW 2005/2006 Work and Time Study I Work and Time Study II 4 Application of time data Areas of Application Purpose of time data: Work planning To select suitable processes, means, and methods Pre-calculation To determine estimated piece prices, budgets Scheduling To minimize delays, to calculate and monitor the delivery deadlines Workplace and machine occupation To optimize the exploitation of capacity, to design workplaces and machines Material delivery To optimize the availability of materials and to plan the stock Personnel planning To plan employee capacity, work schedules and production programs Cost accounting To calculate the manufacturing costs and sell prices, to balance projects, and departments, etc. (economic parameters) Payment © IAW 2005/2006 To determine piece-per-hour production rate, to set the wage per unit and bonuses 5 Classifying Production Operations according to facilities, work piece, or working person In order to obtain information / data for the individual departments of the organization, it is necessary to describe the various procedures and processes in terms of time: When production procedures and processes are classified according to… • the working person, the activities of one employee within a specific time period are analyzed. Work order time • the production facilities, the status of machines, equipment, etc. is regarded. Holding time • the product or work piece which is manufactured, the production cycle of an assembly / product is described in terms of time. Lead time Different time © IAW 2005/2006 types 6 Classification of procedures and processes according to the production facilities utilization In use Not in use Production facilities BI BL B Plant closed BT Interruption of utilization Main utilization BH Ancillary utilization BN Additional utilization BZ Interruption due to the cycle BA Interruption due to dysfunction BS Interruption due to recreation BE Interruption due to personal reasons BP BK BR BX Not identifiable © IAW 2005/2006 REFA 1997 7 Classification of procedures and processes according to the production facilities Main utilization BH ... is the regular and direct utilization of the production facilities according to the purpose (e.g. drilling with a drilling machine). Ancillary utilization BN ... is a regular and collateral utilization of the production facilities as a preparation for the main utilization(e.g. exchanging drill). Additional utilization BZ ... Is the main and ancillary utilization of the production facilities, whose occurrence and cycle is not to be pre-determined. Interruption due to the cycle BA Production facilities wait regularly for the activity of the working person, for the changing of work pieces, or for the termination of certain cycle sections with other production facilities. Interruption due to dysfunction BS ... is additional waiting of the production facilities due to technical and organizational dysfunctions. Interruption due to recreation BE The utilization of the production facilities is interrupted by the recreation of the working person. Interruption due to personal reasons BP The utilization of the production facilities is interrupted by the interruption of the working person due to personal reasons. © IAW 2005/2006 REFA 1997 8 Classification of procedures and processes according to the work piece Modifying Affecting AE Conveying AF Additional modifying AZ Checking Work piece AP A Lying due to the cycle AA Additional (miscellaneous) lying AS Lying © IAW 2005/2006 Mounting AL Not identifiable AX REFA 1997 9 Classification of procedures and processes according to the work piece Affecting AE ... is a modification of the form or state of work pieces. ... is the modification of work pieces concerning position (handling) and location (transportation). Conveying AF Additional modifying AZ ... is affecting and conveying, whose occurrence and cycle is not to be pre-determined. Checking AP ... is the controlling of work pieces in the material flow. Lying due to the cycle AA ... arises, if modifying and checking of the work pieces is interrupted due to the cycle. Additional (miscellaneous) lying AS ... arises, if modifying and checking of work pieces is interrupted due to dysfunctions. Mounting AL ... is the lying of work pieces in the storage areas. © IAW 2005/2006 REFA 1997 10 Classification of procedures and processes according to the working person Activity On duty Off duty Working person MI ML M Plant closed MT Interruption of activity Main activity MH Ancillary activity MN Additional activity MZ Interruption due to the cycle MA Interruption due to dysfunction MS Interruption due to recreation ME Interruption due to personal reasons MP MK MR MX Not identifiable © IAW 2005/2006 REFA 1997 11 Procedure Categorization based on the working person Main activity: planned activity, directly related to the task processing the piece assembling the parts repairing the vehicle © IAW 2005/2006 Ancillary activity: planned activity, indirectly related to the task clamping pieces adjusting apparatus unpacking and if applicable pre-assembling spare parts Additional activity: unforeseeable activity refinish a work piece new calibration of assembly robot repeated order of spare parts if delivery defective 12 Procedure Categorization Based on the the working person Interruption due to the cycle (Allowable delays): Regular waiting period occurring when a machine or device needs time to complete a procedure autonomously. automatic tool changing from repository awaiting drying after washing Interruption due to dysfunction (Non-allowable delays) Unscheduled waiting periods due to technical and organizational dysfunctions waiting for a locksmith electrical power outage Interruption due to recreation: Interruption of an activity due to reduce fatigue Interruption due to personal reasons: Interruption or delay of an activity due to personal reasons smoking a cigarette using the lavatory delayed start of work © IAW 2005/2006 13 Example: Classification of procedures & processes for working person, production facilities, and work piece No. Process section Working person Production Work facilities piece 1. Clamping work piece in bench vice. MN BA AF 2. Drilling a hole into the work piece. MH BH AE 3. Controlling the cross section dimension of the drilling hole by using a caliper gage. MN BA AP 4. Labeling work piece in terms of color. MN BA AE 5. Removing the shavings from bench vice and MN work piece by using a hand brush. BA AA 6. Dismantling the work piece from bench vice and placing it in a box. BA AF © IAW 2005/2006 MN 14 Classification Based on the working person’s activity Type of time Type of activity Main activity Σ t MH Ancillary activity Σ tMN Additional activity Σ tMZ Interruption due to the cycle Σ tMA Interruption due to dysfunction Σ tMS Interruption due to Recreation Σ tME Interruption due to personal reasons Σ tMP © IAW 2005/2006 Time for activity t t Basic time t g Waiting time tw Recreation t re time Objective t additional time s Time per te unit Additional tv time Personal t additional time p REFA 1997 15 Time classification for the work order time Work order time T (allowed time for the working person) Set-Up time tr Execution time ta = m * te Time per unit te Basic time trg Recreation time trer Additional time trv Basic time tg Recreation time ter Additional time tv Further classification is possible Time for activity tt © IAW 2005/2006 Waiting time tw objective additional time ts personal additional time tp REFA 1997 16 Methods for the determination of time data Determining time Analytical-experimental methods (ACTUAL TIMES) observation self-report • manual time measurement - stopwatch - REFA procedures • made by the worker • work sampling (time measurement by means of statistical analysis) – ratio delay – methods for time measurement – ... • interview techniques – list of activities, their duration, and the frequency of their occurrence based on equipment used • with the aid of devices (e. g., computer log-files) Statistical time models © IAW 2005/2006 Analytical-computational methods (TARGETED TIMES) comparison and estimation • Comparison of the work procedures for which the time standards are to be determined with similar activities for which time standards have already been set. • The estimation is based on standard times for the procedure based on historical records or experience (comparative estimation). compilation • systems of predetermined times - Methods Time Measurements (MTM) - Work Factor (WF) calculation of work cycles • based on formulas (e.g., for turning) • based on nomographs • standard times - catalogue of task times - nomograph Sequence-analytical time models 17 Structure: Work and Time Study 1 Work and Time Study - Basics 2 REFA - Stop Watch Time Study 3 Work Sampling method 4 MTM method 5 MTM method - Case Study 6 Conclusion © IAW 2005/2006 Work and Time Study I Work and Time Study II 18 Subject of the REFA Stop Watch Time Study method A stop watch time study is the determination of allocated times by measuring and analyzing actual times. A stop watch time study consists of: the description of the work system (procedure, working method, working conditions), the determination of allocation bases, influencing variables, performance rates, and actual times for individual process sections, and the analysis of this data to determine targeted times for certain process sections. © IAW 2005/2006 19 REFA Standard Program Stop Watch Time Study (1) 1. Determining the purpose of the stop watch time study 2. Preparing the stop watch time study 3. Making a choice between progress-times measurement and individual-times measurement 7. Is an automatic recording time measuring device utilized? yes Accomplishing the time study according to the type of the time measurement device no © IAW 2005/2006 4. Selecting the time measuring device 5. Selecting the time study sheet as per operational sequence REFA 1997 20 REFA Standard Program Stop Watch Time Study (2) cyclic operational sequence 6a Sampling and describing the sequence in consideration of the purpose of the stop watch time study, determining measuring points 6. 7. yes Are operational sequences no with regular recurrences existent? 6b Taking in allocation bases and influencing variables 6c Accomplishing the stop watch time study © IAW 2005/2006 Non-cyclic operational sequence Describing working tasks, - procedures,methods and conditions Accomplishing time study: Sampling and describing the sequence in consideration of the purpose of the stop watch time study; determining measuring points; taking in allocation bases and influencing variables; measuring actual times and appraising performance rates 8. Analyzing stop watch time study 21 Clamping in next piece Releasing Unclamping and Depositing piece Releasing Processing piece Machine stopped Clamping in piece Releasing Process sections Measurement REFA Standard Program Step 3 Ti1 = 30 HM Ti2 = 30 HM Determined time per unit ti (in HM) 0 Ti3 = 25 HM 30 0 Ti4 = 35 HM 30 0 25 0 F1 F2 F3 F4 30 60 85 120 Ti1 = 30 HM Ti2 = 30 HM Ti3 = 25 HM Determined progress time F (in HM) 0 Calculated time per unit ti 35 Ti4 = 35 HM HM - 1/100 minutes (a hundredth minute) © IAW 2005/2006 22 REFA Standard Program Step 7 Situation: Workers differ in their performance rates. Worker A assembles 12 components per hour. Worker B assembles only 10 components per hour under the same conditions. Problem: How can a performance standard be determined (targeted performance = 100%), that can be used for production and operation scheduling and also be met by all workers? Solution: Observation of the activities with regard to their intensity and effectiveness Performance rate (appearance) © IAW 2005/2006 = Intensity is manifested by • speed of movement • physical exertion Effectiveness: is assessed in terms of how • rhythmically • harmoniously and • rapidly work is performed 23 Structure: Work and Time Study 1 Work and Time Study - Basics 2 REFA - Stop Watch Time Study 3 Work Sampling method 4 MTM method 5 MTM method - Case Study 6 Conclusion © IAW 2005/2006 Work and Time Study I Work and Time Study II 24 The subject of work sampling Work Sampling (German: Multimoment) multum (lat.) ~ much momentum (lat.) ~ moment Definition: The work sampling study is a sampling method which provides estimations for the relative frequency, as the case may be for the duration of predominantly unsteady occurring work processes, or for similar sizes with a • arbitrary accuracy together with a • statistical confidence (level of significance) α. © IAW 2005/2006 25 Work sampling methods Work sampling methods (MM) Work sampling ratio delay (MMH) Counted measurands Absolute percentage frequency rates © IAW 2005/2006 11 12 1 10 2 9 3 8 4 7 6 5 Work sampling by methods of time measurement (MMZ) Measured values Minute-values Hour-values 26 Principle of Work Sampling Three work processes are distinguished, which are encoded in terms of color in white, grey, or black in the schedule. The work processes’ as the case may be activities’ proportions of the labor time is to be determined. Begin of tours 8h First annotation 9h 10h 11h 12h 13h 14h Last annotation B C D Lunch Break Workstations A E Number of observations of the incidents End of tours 15h 16h 17h t1 t2 t3 321 74 85 354 63 63 361 55 64 348 98 34 363 72 45 73 15 12 p̂ 1 p̂ 2 p̂ 3 min T= 40 hours ≡ 100 % Stop watch time study Working time Time % proportions as a result of the time study Work sampling study n1 70 n2 p̂ 1 17,5 p̂ 2 12,5 p̂ 3 n3 N = 40 annotations ≡ 100 % n3 5 = N 40 Estimation of the probability according to frequency observations Source: Haller-Wedel (1969) © IAW 2005/2006 27 REFA standard program work sampling I Determination of target II Determination of types of action III Determination of tour plan IV Determination of necessary amount of observations N‘ Accomplishment of further observations V Determination of tour terms Calculation of necessary amount of observations N‘ VI Accomplishment of N = 500 observations no yes VII Interim analysis © IAW 2005/2006 f < f‘? VIII Final analysis REFA 1997 28 Approximation of the binomial distribution by normal distribution p (ni ) f ( x) Probability N→∞ Moivre-Laplacetheorem 1 2 3 4 5 6 0 Number of observations ni with N annotations for p1=p2=0,5 Normal distribution Probability density Binomial distribution -σ μ σ x Characteristics of the normal distribution • The graph of the distribution proceeds bell-shaped and is axially symmetric regarding the expected value μ (average value) • Expected value μ, mode and median coincide • The differences between the distributions are to be ascribed to two parameters, scilicet expected value (average value) and standard deviation (dispersion): Expected value μ : barycenter of the distribution ∞ μ = E( x) = ∫ x f ( x)dx Standard deviation σ : dispersion about the barycenter (kurtosis) σ = E ( ( x − μ )2 ) −∞ © IAW 2005/2006 29 MMH – Probability of error Starting from the barycenter μ of the normal distribution, approx. 68% of any cases are to be expected in the interval [μ - σ ; μ - σ]. Due to the rapidly dispersing distribution, 95,5% of the cases are already covered in the duplicate interval [μ - 2σ ; μ - 2σ] („Two Sigma“). The probability α, that observations are located outside the Two-Sigma-Interval is only approx. 4,5%. The variable α is referred to as probability of error. Analogical, each probability of error α corresponds to a certain sigma interval [ − z α / 2 σ ; z α / 2 σ ] . The value 1-α indicates the area A below the bell-shaped curve in the sigma interval. f ( x) A= zα / 2 ∫ f ( x)dx − zα / 2 Standardized normal distribution with μ=0 und σ=1 ≡ 1−α − zα / 2 -2σ zα / 2 -σ μ σ 2σ x 68 % -1,96σ © IAW 2005/2006 95,5 % 95 % 1,96σ 30 MMH – Basics of the estimation • Within the MMH procedure, a probability of error α is required - typically 5% - which should not be exceeded within the estimation of the proportion pi of the activity i in which we are interested, with the accuracy fi..Consequently, the required interval is [pi –fi ; pi +fi ]. • Due to the probability of error α, it is possible to determine the corresponding sigma intervals [ − z α / 2 σ ; z α / 2 σ ] by dint of the standardized normal distribution. As to be recognized on the previous slide, i.e. the sigma interval for α=0,05 is approx. [-1,96σ ; 1,96σ]. • Moreover, it is to be considered that the estimated value of the proportion of the activity i in which we are interested is not standard normal distributed, but shows the average value pˆ i and a dispersion sˆi . • Previous to the MMH data collection the relative activity proportions pˆ i have to be estimated plausibly by the observer according to his experiences. If observations are already available (i.e. N=500 in the REFA standard program), the probability simply will be estimated according to the principle of maximum likelihood by the relative frequency: pˆ i = ni N • If no observations are available, the accuracy boundaries –fi as the case may be + fi will be used instead of a subjective estimation. If data was collected, the following estimation according to the principle of maximum likelihood would be utilized: sˆi = © IAW 2005/2006 pˆi (1− pˆi ) N 31 MMH - Main Formula Finally, the MMH main formula can be affiliated. This is an interval estimation of the proportion pi of the activity i with the required accuracy fi around the mean of the interval with a probability of error α ( P(true value of pi is located in the interval) = 1-α ) ): [ pˆ i − f i ; pˆ i + f i ] The accuracy can easily be expressed as sigma interval: f i = z α 2 sˆi m it z α with 2 = 1, 96 for für α = 5% The MMH main formula for the necessary sample size N with estimated activity proportions pˆ i , the required accuracy fi and the probability of error α is: sˆi = Previous to the MMH observations: N '= © IAW 2005/2006 zα 2 2 pˆ i ′ (1 − pˆ i ′ ) f ′² pˆ i (1 − pˆ i ) pˆ i (1 − pˆ i ) ⇔ N = N sˆi 2 After the MMH observations: N = zα 2 2 pˆ i (1 − pˆ i ) f² 32 Example: MMH in large firms of the retail industry Verkäufer (alle Sales clerk (allMärkte) markets) Hauptprozess "Interaktion mitwith demthe Kunden" Primary process "Interaction customer" 50,00 45,00 40,00 p [%] 35,00 30,00 25,00 20,00 15,00 10,00 5,00 0,00 8am-08.00 9am 09.00 9am09.00 10am 10.00 10am 11am noon10.00 - - 11.00 - - 12.00 11am 12.00 noon 1pm 11.00 13.00 1pm -13.00 2pm 14.00 2pm -14.00 3pm 15.00 3pm -15.00 4pm 16.00 4pm -16.00 5pm 17.00 5pm -17.00 6pm 18.00 6pm -18.00 7pm 19.00 7pm -19.00 8pm 20.00 time Uhrzeit N=178 N=920 N=888 N=931 N=1094 N=1064 N=1238 N=1002 N=910 f= 3,4% f=3,0% f=3,1% f=3,0% f=2,7% f=2,6% f=2,4% f=2,8% N=905 N=601 N=482 f=3,1% f=3,1% f=4,0% f=4,3% Observations in three markets, six days each MMH as the basis of a related-to-need short-term manpower planning © IAW 2005/2006 Hinrichsen, Peters, Schlick 2005 33 Work Sampling method: Advantages and Disadvantages Advantages Representative image of the actual state Comprehension of a large amount of workstations is possible Comparatively low expenditure of time in comparison to the stop watch time study No measuring instruments necessary Disadvantages Time-influencing variables and reasons for actual times are not directly apparent from the results of the study Annotations are based on non-recurring observations and thus are not to be verified later on Performance rates are not to be measured Results are to be manipulated by observing persons © IAW 2005/2006 34 Questions of learning success 9 What are the operational purposes of time data in companies? 9 How are the REFA activities basically structured? 9 Which types of activities can be distinguished regarding working persons, production facilities and products? 9 How is the work order time (allowed time for the working person) structured? 9 Which methods for the determination of time data can be distinguished? 9 What are the basic characteristics of the REFA - Stop Watch Time Study? 9 How is the performance rate defined? 9 What are basic characteristics of a work sampling method? © IAW 2005/2006 35 Lehrstuhl und Institut für Arbeitswissenschaft der RWTH Aachen Industrial Engineering, Ergonomics & Work Organisation Exercise Unit 4 Work and Time Study I winter term 2005/2006 Univ.-Prof. Dr.-Ing. Christopher Schlick Classes of operations Task 1 An A bearing surface has to be milled on work pieces in a limited-lot production. In order to improve the efficiency of the production processes, Mr. Schulze from Industrial Engineering carries out an analysis of the actual times of the process. To do so he observes the process and notes single activities of the process. Help Mr. Schulze by matching the activities of the production process in table 1 with the corresponding classes of operations (MH, MN, MZ etc.). (Use figure 1 as a help!) © IAW 2005/2006 37 Figure 1 Principal activity Activity On duty Off duty Working person MI ML M Plant closed MT Interruption of activity MK MR Not identifiable © IAW 2005/2006 MH Ancillary activity MN Additional activity MZ Interruption inherent to the cycle MA Interruption due to dysfunction MS Interruption due to recreation ( ME Interruption due to personal reasons MP MX 38 Table 1 Nr. Activities 1. Read job order and graph 2. Take cutter, clamp cutter and set milling machine 3. Take work piece and clamp work piece 4. Supervise milling and first cut 5. Milling without supervision 6. Unclamp work piece 7. Check the surface quality of the work piece (planned visual inspection) Deposit work piece 8. 9. 10. © IAW 2005/2006 Class of Operation Unscheduled changing of the cutter, because the surface quality of the work piece has degraded due to abrasion of the cutter Foreman introduces a new colleague to the employee at the milling machine 39 Time Classification based on the working person’s behavior Task 2 Calculate the job order time allowed for the manufacture of 300 pieces of steel protective caps. Thereby use the REFA Time Classification based on the working person‘s behavior. © IAW 2005/2006 40 Time Classification based on the working person’s behavior job joborder order time timeallowed allowed TT time timeallowed allowed tat ==mm* *tet Set Setup uptime time trt r a e time timeper perunit unit tet e Set Setup upbasic basictime time trg trg Set Setup up recovery recoverytime time trer t rer Set Setup up additional additionaltime time trv t basic time basic tgt time g rv recovery recovery time time ter ter Additional Additional time time tvt v further classification possible activity activity time time ttt t influencable influencable activity activitytime time ttb ttb © IAW 2005/2006 waiting waiting time time twt w object-related object-related additional additionaltime time tst s worker-related worker-related additional additionaltime time tpt p non - -influencable non influencable activity activitytime time ttu ttu 41 Time Classification based on the working person‘s behavior Task: Input: Production of steel protective caps Blank plates Drawing -Nr. 026/417 Equipment: 800 t - drawing press Batch size m: 300 pieces Additional time rate zv: 7% Recovery time ter: 0.015 min/piece no set up recovery time and no set up additional time Procedure for one work cycle (number of units 1) incl. set up the machine: Nr. Operations 1 2 3 4 5 6 7 8 Mount stamping tool in press Test and control press Grasp plate and transport it to press Insert plate into die Operate press with both hands, stamp Remove protective cap from the die Set protective cap down Walk from transporting rig to pallet 8.00 1.30 0.10 0.05 0.15 0.08 0.06 0.06 9 Dismantle tool 5.00 © IAW 2005/2006 Targeted time in min 42 Work Sampling Task 3 In a work sampling study for the optimization of setup time which is to be accomplished by Mr. Mueller, 45 injection molding machines should be included. How many tours are necessary, if a probability of error of at most 5% should form the basis of the result. Please act on the assumption that a total deviation f‘ of 1.5% is not to be exceeded. Hint: Within the last measurement, the setup time had a part of 15%. The following is imperative: 3.84 ⋅ p '⋅ (100 − p ' ) N '= f '² © IAW 2005/2006 N´ = Total number of necessary annotations p´ = Expectancy value as percentage f´ = Desired spread as the case may be tolerated error 43