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05 Direct Time Study

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49 views20 pages

05 Direct Time Study

Uploaded by

Hendry Susanto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Methods engineering

and operational analysis (Part 1)


Work measurement and task hierarchy

• How the work measurement techniques correspond to different


levels in the general task hierarchy.
task hierarchy level Work Measurement Technique

Work sampling

Direct time study/stopwatch time study

Predetermined time system


Direct (me study
• Direct and continuous observation of a task using a stopwatch or
other timekeeping device to record the time taken to accomplish a
task.
• also known as stopwatch time study

• While observing and recording the time, an appraisal of the worker’s


performance level is made to obtain the normal time for the task.
• The data are then used to compute a standard time for the task.

• It is much more appropriate for repetitive tasks (batch and mass


production)
Methodology
• Who to choose?
• Select an Average Worker
(What is average?)
• Experienced Worker
• Normal pace
• Consistency (well defined, understood by
all)
• No undue strain for entire day
(speed/effort)
• Pace that should be performed, not
average of current rate
• Worker acceptance
Equipments
• Decimal minute stopwatch
• Decimal hour stopwatch
• Motion picture camera
• Videotape equipment / video player
• observation sheet
Direct Time Study Procedure
1. Define and document the standard method
2. Divide the task into work elements
3. Time the work elements to obtain the observed time Tobs
4. Evaluate worker’s pace relative to standard performance (Performance
rating) to obtain normal time (Tn)

Step 3 & 4 are (sometimes) performed simultaneously, several times


Tn = Tobs * PR
Then, the values collected in step 3 & 4 are averaged.

5. Apply allowance factor to compute standard time


Tstd = Tn * (1 + Apfd)
Define and document the standard method

• Goal: “one best method”


• Seek worker’s advice, if appropriate
• Elements of Document
• Procedure (steps, actions, work
elements, hand/body motions)
• Tools, equipment
• Machine settings (e.g., feeds, speeds)
• Workplace layout
• Frequency of irregular elements
• Working conditions
• Setup
Define and document the standard method

Why thorough documentation of the standard method is important?


• Batch production.
• Batch production is likely to be repeated at some time in the future.
• Methods improvement by the operator.
• The operator may discover a way to improve the method.
• Disputes about the method.
• Sometimes operator complains about the standard.
• Data for standard data system.
• Good documentation of standard method is essential in developing the
database for a standard data system
Divide the task into work element
How to define work elements?
1. Each work element should consist of a logical group of motion
elements
2. The beginning point of one element should be end of previous.
3. Each element should have readily identifiable end point.
4. Work elements should not be too long (< “several” min) and not be
too short (≥3 sec)
5. Irregular elements should be identified & distinguished.
6. Manual elements should be separated from machine elements.
7. Internal elements should be separated from external elements
Divide the task into work element
• Separate between “Irregular” and
“Foreign” Elements:
• Irregular elements
• elements that occur routinely, but not
every cycle
• should be included in time
measurement
• Foreign elements
• Elements that are not normal work –
should not be included
Time the work elements

observed time

work elements
performance rating

normal time

irregular elements
Timing Methods
• Continuous method
• Advantage: Clock never stops, no time
omitted
• Disadvantage: observer does not know at
the job how individual elements vary
• Snapback method
• Advantage: Observer can note individual
variability within an element and eliminate
subtraction
• Disadvantages: difficult to coordinate eye,
watch and task! Especially when operations
are short
Rate the worker’s performance
• Standard performance = 100%
• Rate
• Individual elements
• Or entire work cycle
• Most difficult & controversial
step in time study
• Requires analyst’s judgment
Rate the worker’s performance
• Westinghouse rating factor:
• One of the oldest used rating systems, then termed leveling, was developed
by Westinghouse Electric Corporation.
• This Westinghouse rating system considers four factors in evaluating the
performance of the operator: skill, effort, conditions, and consistency.
Apply allowance to normal time to
compute standard time (Tstd)
• to apply standard time for the task, PFD allowance is added to the
normal time
Tstd = TN * (1 + Apfd)

Apfd —> allowance factor for personal Bme, faBgue, and delays

➤ in case the task includes a machine cycles, the standard time may be
computed as

Tstd = TNW * (1 + Apfd) + TM * (1+AM)

AM —> machine allowance factor (delay, setup, breakdown etc)


Example: determining a standard
time for pure manual work
A direct time study was taken on a manual work cycle using the snapback timing
method. The regular work cycle consisted of three elements, identified as a, b, and
c in the following table. Element d is an irregular element performed every 5 cycles.
Observed times and performance ratings of the elements are also given. Determine
(a) the normal time and (b) the standard time for the work cycle, using an
allowance factor of 15%.
Example: standard time for a task
that includes a machine cycle
The snapback timing method was used in a direct time study of a task that includes
a machine cycle. Elements a, b, c, and d are performed by the operator, and
element m is a machine semi- automatic cycle. Element b is an internal element
performed simultaneously with element m, and element d is an irregular element
performed once every 15 cycles. Observed times and performance ratings are given
in the table below. The PFD allowance factor is 15%, and the machine allowance is
20%. Determine (a) the normal time and (b) the standard time for the work cycle.
Determining number of cycles
• Time measurement
• Measuring Yme of each element
• The number of observaYon of each
element depends on the significance
level and required level of accuracy
How many sample/cycles?

• overall,
• our objecYve is to find the value of sample size n that will saYsfy our specificaYon
of 𝜶 and interval size for the values of x and s.
• let’s say, if the interval size = x̄ ± k x̄, , where k is a proporYon of the specified
interval (e.g. 10% or 0.10), then we may have
How many sample/cycles?
• A time study analyst has collected 10 readings on a particular work element of
interest and would like to consider how many more cycles to time. Based on the
sample, the mean time for the element is 𝑥̅ = 0.40 min and the sample standard
deviation s = 0.07 min. At a 95% confidence level, how many cycles should be
timed to ensure the actual element time is within ± 10% of the mean?

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