Procedures of Method Study Part-1

Method study is basically conducted to simplify the work or working methods and must go towards higher productivity. It is always desirable to perform the vital function with desired goal minimum consumption of resources. Method signifies how a work is to be done, i.e. description of how we consume resources in order to achieve our target?

Procedures of Method Study:

Select:

Work Selected for methodical study may be an identified problem area or an identified opportunity. It may be identified through a systematic review of obtainable data, normal monitoring or control processes. High levels of dissatisfaction and complaint or as part of a change in management policy, technology or location, and usually because it meets certain conditions or urgency and/or priority.

Recording:

The Record stage of method study involves gathering sufficient data to act as the basis of evaluation and examination.

Different types of Recording Techniques:

Indicating Process Sequence:

1.      Outline Process Chart

2.      Flow Process Chart. Man Type, Material Type, Equipment Type.

3.      Two Handed Process Chart.

Using Time Scale:

1.      Multiple Activity Chart, Using Time Scale.

2.      Simo Chart, Using Time Scale.

3.      P.M.T.S Chart

Diagrams Indicating Movements:

1.      Flow Diagrams.

2.      String Diagram.

3.      Cycle graph.

4.      Chrono-cycle graph.

5.      Travel Chart.

Chart:

Symbols Used in Charts:

Operation: Indicates the main steps in a process, method or procedure. Usually the part, material or product concerned is modified or change during the operation.

Inspection: Indicates an inspection for quality and/or check for quantity.

Transport: Indicated the movement of workers, materials or equipment from place to place.

Temporary Storage Or Delay: Indicates a delay in the sequence of events: for example, work waiting between consecutive operation or any object aside temporarily without the record until required

Permanent Storage: Indicates a controlled storage in which material is received into or issued from a store under some form of authorization; or an item is retained for reference purposes.

Outline Process Chart:

An outline process chart is a process chart giving an overall appearance of a process by recording the main operations and sequences in appropriate Operations & Inspection.

While Preparing the outline process chart we use Symbols of Operation and Inspection.

A Brief note of the nature of each operation is made beside the symbol.

In an outline process chart, only the principal operations and the inspections carried out are recorded to ensure effectiveness.

An Operation process chart is a graphic representation of the sequence of all operations and inspections taking place in a process. It gives a bird’s eye sight of the overall activities. Entry points of all material, the sequence of all operations and inspection associated with the process are noted in the chart.

An Operation Process Chart Has The following uses:

(1)   Improved plant layout.

(2)   For specifying the basic manufacturing system.

(3)   For determining the sequence of assembly.

(4)   To introduce a manufacturing system to new technical personnel.

Flow Process Chart:

Flow Process charts are graphic representations of the sequences of operations, transportation, inspections, delays and storages occurring during a process or a procedure and include information considered for analysis such as, time required and distance moved. A flow process chart can be prepared in a similar manner as to prepare the outline process chart. A flow process chart is a process chart indicating the sequence of the flow of a product by recording all the events with the help of process chart symbols.

To develop an understanding how a process or work happening and clearly documenting how a particular job is done, in addition of that mapping a process in flow chart format helps us where the process can be improved.

There are Three Types of Flow Process Charts:

1.       Material or Product type or equipment.

2.       Man type.

3.       Machine type or equipment.

Material or Product type flow process chart:

Records what happens to the material or product, i.e. the changes the material or product undergoes in location or condition (includes operation and transportation).

Man Type Flow Process Chart:

Records the activities of the worker or operator, i.e. what a worker or operator does. To this type of chart usually the storage term is not applicable.

Machine or equipment type flow process charts:

Records the manner in which a machine or an equipment is used.

General Guidelines For Making A Flow Process Chart:

a.      The details must be obtained by direct observation-chart must not be based on memory.

b.      All the facts must be correctly recorded.

c.       No assumptions should be made.

d.      Make it easy for future reference.

e.      All the charts must have the following details:

1.      Name of the product, material or equipment that is observed.

2.      Starting point and ending point.

3.      The location where the activities take place.

4.      The chart reference number, sheet number, and number of total sheets.

5.      Key to the symbols used must be stated.

Objective of Flow Process Charts:

1.      Set out a sequence of flow of events occurring in the process.

2.      To study the event in a systematic way.

a.      To improve the layout.

b.      To improve material handling.

c.       To reduce delays.

d.      To eliminate, combine or rearrange the events in a systematic way.

3.      To compare between two or more alternative methods.

4.      To select operations for detail study.

Two-handed Flow process chart:

Two-handed flow process chart, is a motion study where the study is done to analyze the motions used by a worker in performing an activity.  The aim of this investigation is to eliminate or reduce the unwanted motion to a minimum and to arrange the best motions in a possible sequence. The Two-handed process chart is also known as Left and Right Hand process chart. In this chart the activities of a worker’s hands are recorded in their relationship to one another.

A Two-handed process flow chart individually shows the movement of each hand in a manual process. It is typically used for repetitive operation when analyzing a manual assembly process, to help make it easier to perform.

General Guidelines For Preparing the Two-handed process flow chart:

1.      Provide all information about the job in the chart.

2.      Study the operation cycle a few times before starting to record.

3.      Record one hand at a time.

4.      First record the activities of the hand which starts the work first.

5.      Do not combine the different activities like operations, transport etc.

In summary, the two-hand process chart is an effective tool:

1.         Balance the motions of both hands and reduce fatigue.

2.         Reduce or eliminate nonproductive motions.

3.         Shorten the duration of productive motions.

4.         Train new operators in the ideal method.

5.         Sell the proposed method.

Edited By:

Md. Farid Ahmed

IE Officer 

Fakir Apparels Ltd.

BSCIC Industrial Area, Enayet Nagar,

Fatulla, Narayangonj, Bangladesh.