Unit 2 Industrial Engineering & Management Notes in English

 These are short notes for revision purpose. please refer you Reference book & College study materials for complete study.

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2. Work Study

Work Study is a systematic approach to improving productivity, efficiency, and effectiveness in the workplace. It focuses on analyzing work processes, methods, and time management to optimize the use of resources. Work study involves two major components: Method Study and Work Measurement. Let’s explore these topics in detail.

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2.1 Productivity

Productivity is a measure of how efficiently inputs are converted into outputs. It is calculated by the formula:

$$\text{Productivity} = \frac{\text{Output}}{\text{Input}}$$

Higher productivity means more goods or services are produced with fewer resources. Improving productivity is a major goal of work study as it helps reduce costs and improve efficiency in manufacturing and services.

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2.2 Standard of Living

The standard of living refers to the quality and quantity of goods and services available to a population, along with the ability of individuals to access those goods and services. Productivity improvements in industries contribute to a higher standard of living as they often lead to lower prices, more goods, and better wages for workers.

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2.3 Methods of Improving Productivity

Improving productivity involves various strategies that can be implemented in a workplace, including:

1. Improving methods: Streamlining processes and eliminating waste.
2. Training employees: Enhancing workers’ skills to increase efficiency.
3. Automation: Using machines to replace manual labor.
4. Improved work conditions: Reducing fatigue and enhancing worker comfort.
5. Motivating workers: Encouraging workers to perform at their best through rewards or incentives.

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2.3.1 Objectives of Improving Productivity

The key objectives of improving productivity are:

• Minimize waste: Use resources more efficiently.
• Increase efficiency: Perform tasks faster with fewer errors.
• Increase output: Produce more with the same or fewer resources.
• Enhance product quality: Maintain or improve the quality of products while reducing costs.
• Improve working conditions: Make the workplace safer and more comfortable for employees.

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2.4 Importance of Good Working Conditions

Good working conditions are crucial for improving productivity and ensuring worker satisfaction. Benefits include:

• Enhanced morale: Comfortable working conditions increase employee satisfaction and motivation.
• Reduced absenteeism: Better environments lead to fewer sick leaves and higher attendance.
• Improved health and safety: Reduces the risk of accidents, injuries, and long-term health issues.
• Increased efficiency: When employees are comfortable and safe, they perform better and work faster.

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2.5 Method Study

Method Study is the systematic recording and analysis of existing methods and finding ways to improve them for greater efficiency.

2.5.1 Definition

Method Study is a technique used to improve the efficiency of work by analyzing and optimizing the methods used in the production process.

2.5.1.1 Objectives of Method Study

The main objectives of Method Study are:

• Improve productivity: Reduce unnecessary steps and time.
• Simplify operations: Make the process easier and quicker.
• Standardize work methods: Establish the best and most efficient way to perform tasks.
• Reduce costs: Minimize waste in terms of time, materials, and energy.

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2.5.2 Selection of a Job for Method Study

Jobs are selected for Method Study based on the following criteria:

• High labor cost: Jobs that consume a lot of time or effort.
• Repetitive operations: Jobs that are performed regularly and can benefit from optimization.
• Quality problems: Jobs that produce defects or require rework.
• Potential for improvement: Jobs where efficiency gains can be significant.

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2.5.3 Basic Procedure for Conduct of Method Study

The basic steps involved in Method Study are:

1. Select the work: Choose the task or process for study.
2. Record the existing method: Collect data on the current process using charts, diagrams, and direct observation.
3. Examine the recorded data: Analyze the data to identify inefficiencies, delays, and waste.
4. Develop improved methods: Propose changes to make the process more efficient.
5. Install the new method: Implement the improved process.
6. Maintain the new method: Ensure continuous monitoring to maintain efficiency gains.

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2.5.4 Tools Used in Method Study

1. Operation Chart: Records the sequence of operations in a process, helping identify unnecessary steps.
2. Flow Chart: A diagram that represents the flow of materials, information, or tasks in a process.
3. Two-handed Process Chart: Used to study the movements of both hands of an operator during work to improve efficiency.

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2.5.5 Man-Machine Chart

A Man-Machine Chart records the interaction between an operator (man) and a machine. It helps identify:

• The time spent by the operator on the machine.
• Idle time of both man and machine. This chart is useful for balancing the workload and improving productivity.

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2.5.6 String Diagram

A String Diagram is used to record the movement of a worker or material within a specific area. It helps visualize the path taken during work and can identify unnecessary movements that waste time and effort.

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2.5.7 Flow Diagram

A Flow Diagram is a graphical representation of the steps in a process or workflow. It shows the sequence of operations and the interactions between different stages of production. It helps in visualizing the entire process and identifying inefficiencies.

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2.6 Work Measurement

Work Measurement involves determining the time required to perform a task. It helps in setting performance standards, calculating labor costs, and improving efficiency.

2.6.1 Definition

Work Measurement is the process of determining the time required to perform a specific task, using standardized methods and tools.

2.6.2 Basic Procedure in Making a Time Study

The basic procedure for making a time study includes:

1. Select the job: Choose the task to be timed.
2. Break the job into elements: Divide the job into smaller, measurable tasks or steps.
3. Record the time: Use a stopwatch or timer to measure the time taken for each element.
4. Calculate the average time: Take multiple readings to calculate the average time per element.
5. Analyze the data: Use the data to improve the method or determine standard time.

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2.6.3 Employee’s Rating Factor

The Employee’s Rating Factor adjusts the time measured in the time study to account for variations in worker performance. It’s used to modify observed times to represent the time it would take for an average worker to perform the task.

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2.6.4 Application of Time Allowances

Time allowances are additional time added to the observed time to account for factors like rest, delays, and learning curves. The common allowances are:

• Personal time: Time for rest and personal needs.
• Fatigue time: Time for recovery from physical exertion.
• Delay time: Time lost due to unforeseen issues (machine breakdown, material shortage).

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2.7 Calculation of Standard Time

Standard time is the time required to perform a task under normal working conditions. It is calculated as:

$$\text{Standard Time} = \text{Observed Time} \times \left( 1 + \text{Allowance Factor} \right)$$

Where the allowance factor accounts for rest, fatigue, and delays.

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2.8 Numerical Problems

Numerical problems in work measurement often involve calculating the standard time, total time for production, or efficiency of workers based on time studies and allowances. You may be asked to:

1. Calculate observed time.
2. Apply rating factors and allowances.
3. Determine standard time and productivity.

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2.9 Basic Concept of Production Study

A Production Study is a detailed analysis of the entire production process to identify areas for improvement. It includes the study of:

• Material flow: How materials move through the production process.
• Worker efficiency: The performance of operators and the time required for each task.
• Machine utilization: How efficiently machines are used in the production process.

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2.10 Techniques of Work Measurement

Work measurement techniques include:

1. Stopwatch Time Study: Observing and recording the time taken to complete tasks.
2. Work Sampling: Observing a worker’s activity at random intervals to estimate the time spent on various tasks.
3. Pre-determined Time Standards (PTS): Using standard time values for predefined activities or tasks.

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2.11 Pre-determined Motion Time System (PMTS)

PMTS is a work measurement technique where the time for basic motions (like reaching, grasping, moving, etc.) is predetermined based on a library of standard times. This system helps in establishing standard times for tasks without conducting a detailed time study.