UNIVERSITY INSTITUTE OF ENGINEERING

DEPARTMENT MECHANICAL
Bachelor of Engineering (Mechanical Engineering)
PRODUCTION PLANNING & CONTROL

DISCOVER . LEARN . EMPOWER

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 LECTURE TOPIC

METHOD STUDY

OBJECTIVES
TO GET FAMILIARIZED WITH FUNDAMENTALS
OF,METHOD STUDY, WORK STUDY & INVENTORY

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 METHOD STUDY

• Method study is the technique of systematic recording and critical examination of

existing and proposed ways of doing work and developing an easier and
economical method.

• It deals with doing the work in a better way, with less time and effort. That is
why it is also termed as work simplification.
 Need of Method Study
• Manufacturing industry uses following resources

• These resources must be used in effective and efficient manner

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Method study

Method study is the systematic recording and critical examination of existing

and proposed ways of doing work as a means of developing and applying easier

and more effective methods and reducing costs.

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 Concept of Method study
• The main purpose of method study is to eliminate the unnecessary operations
and to achieve the best method of performing operation

• Method study is used to describe the set of analysis techniques which focus on
improving the effectiveness of men and machines

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 Concept of Method study

Method study used to analyze :

• Movement of body, People or material

• Activities of peoples and machines

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 Objectives of Method Study
1. Improvement of manufacturing processes and procedures.

2. Improvement of working conditions.

3. Improvement of plant layout and work place layout.

4. Reducing the human effort and fatigue.

5. Reducing material handling

6. Improvement of plant and equipment design.

7. Improvement in the utility of Material, Machines and Manpower.

8. Standardisation of method.

9. Improvement in safety standard

 BASIC PROCEDURE FOR METHOD STUDY

The basic approach to method study consists of the following eight steps.

1.SELECT: The work to be studied and define its boundaries.

2.RECORD: The relevant facts about the job by direct observation and collect such additional

data as may be needed from appropriate sources.

3.EXAMINE: The way the job is being performed and challenge its purpose, place sequence

and method of performance.

4.DEVELOP: The most practical, economic and effective method, drawing on the contributions

of those concerned.
5.EVALUATE different alternatives to developing a new improved method comparing the cost-effectiveness of the

selected new method with the current method with the current method of performance.

6.DEFINE the new method, as a result, in a clear manner and present it to those concerned, i.e., management,

supervisors and workers.

7.INSTALL : The new method as a standard practice and train the persons involved in applying it.

8.MAINTAIN The new method and introduce control procedures to prevent a drifting back to the previous method

of work.
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 Selection of the Job for Method Study

• Cost is the main criteria for selection of a job, process and

department for methods analysis.
• To carry out the method study, a job is selected such that the
proposed method achieves one or more of the following results:

(a) Improvement in quality with lesser scrap.

(b) Increased production through better utilization of resources.
(c) Elimination of unnecessary operations and movements.
(d) Improved layout leading to smooth flow of material and a balanced
production line.
(e) Improved working conditions.
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SYMBOLS USED IN METHOD STUDY
 Example of method study by using symbols
O □ → O □ ∇ D
Assemble -> Inspect -> Move -> Pack -> Inspect -> Store -> Delay
•Assemble the Product Parts (Operation Symbol - Circle):
The process begins with assembling the different components of the product. This step is represented by
the Symbol – Circle.

Inspect the Assembled Product (Inspection Symbol - Square):

After assembly, the product undergoes a quality inspection to ensure it meets required standards.

Move the Product to the Packaging Area (Transport Symbol - Arrow):

Once the inspection is completed, the product is moved to the next station (in this case, the packaging
area).

Pack the Product into Boxes (Operation Symbol - Circle):

At the packaging area, the product is packed into boxes. This activity is another Operation, where
physical work is performed, represented again by the Circle. 13
Inspect the Packaging (Inspection Symbol - Square):

After packaging, a final inspection is performed to check for any damages or issues with the packaging.

Store the Packaged Product in the Warehouse (Storage Symbol - Inverted Triangle):

Once the product passes the packaging inspection, it is placed into storage in the warehouse, ready for
shipment.

Waiting for Shipment (Delay Symbol - D-shaped):

After being stored, the product might wait until it is time for shipment. This delay is represented by the
Delay symbol (D-shaped), indicating a period of inactivity or waiting in the process.

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 CHARTS AND DIAGRAMS USED IN METHOD STUDY
(TOOLS AND TECHNIQUES)
1. Operation process chart (or) Outline process chart.
2. Flow process chart.
(a) Material type
(b) Operator type
(c) Equipment type
3. Two-handed process chart. (or) Left hand-Right hand chart
4. Multiple activity chart.
5. Flow diagram
6. String diagram
 Operation process chart (or) Outline process chart

An Operation Process Chart (OPC), also known as an Outline Process Chart, is a tool used

in industrial engineering and process improvement to map out and analyze a production

process. It provides a visual representation of all the operations and inspections performed on a

product or during a specific process. This chart helps identify inefficiencies, reduce waste, and

streamline workflows.

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 Flow process chart
• Flow process chart gives the sequence of flow of work of a product or any part through appropriate symbols.
• It is the amplification of the operation process chart in which operations; inspection, storage, delay and
transportation are represented.
• Constructed by placing symbols one below another as per the occurrence of the activities and are joined by a
line.

Use of flow process chart helps to improve a work method by

• Elimination or simplification of operations.

• Elimination or simplification of inspections needed or relocation of inspection points.
• Reduced in movement distance of man or materials in shops.
• Reduction in delay or waiting times. 18
 Types Of Flow Process Charts

There are three types of flow process charts

o Flow process chart – Product Analysis

This is a graphic representation of different steps involved in performing the work
required to convert a product from one stage to another.
o Flow process chart – Man Analysis
This is a graphic representation of different steps; a person performs when doing a
job and his movement from one place to another in performing that job.
o Flow process chart – Equipment Analysis
A flow process chart records how the equipment is used. Until, unless clearly
mentioned flow process chart refers to that of flow process chart based on product (material)
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 Used of Flowcharts Method Study
1.Process Visualization: Flowcharts visually represent each step in a process, using standardized symbols to denote actions
such as operations, inspections, transportation, delays, and storage. This allows an easy-to-understand, step-by-step view of how
work progresses, making it simpler to analyze the entire workflow.
2.Identifying Problem Areas: By mapping out the sequence of activities, you can easily spot inefficiencies, delays, or
redundant steps. For example, if there are too many delays or inspections, you might explore why these are necessary and
whether they can be reduced or eliminated.
3.Standardizing Processes: Flowcharts help in documenting standard operating procedures (SOPs). By formalizing a process
in a flowchart, teams can ensure that all workers follow the same steps, leading to consistency and efficiency in operations.
4.Evaluating Work Methods: You can use flowcharts to compare different methods of performing the same task. By creating
flowcharts for each method, you can visually analyze which method is more efficient by comparing the number of steps, delays,
and other activities involved.
5.Facilitating Communication: Flowcharts serve as a common language between different teams and stakeholders. They make
it easier to explain complex processes to others and help build a shared understanding of the workflow. 20
 Information Conveyed by Flowcharts in Method Study

1.Sequence of Operations: Flowcharts show the exact sequence of actions, helping to understand how tasks are
interrelated and what follows what in a process. This clarifies dependencies between steps.
2.Types of Activities: Each step is represented by a specific symbol (Operation, Inspection, Transport, Delay, Storage),
helping to differentiate between the types of activities involved. This helps in categorizing the steps for further analysis,
such as focusing on reducing delays or transportation times.
3.Timing and Flow: Flowcharts can indicate the duration of each activity, how long materials are in storage, or where
bottlenecks occur. It shows how smoothly the process flows and where there are slowdowns or excessive waiting times.
4.Material and Information Flow: Flowcharts depict both the flow of materials (e.g., product parts moving through
different stations) and the flow of information (e.g., approval processes or inspections). This helps in understanding how
resources are utilized and communicated across the process.
5.Potential Areas for Improvement: By visualizing the entire process, flowcharts help identify areas for improvement.
For example, if there are multiple inspections, it may be possible to consolidate or eliminate some, saving time and
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 Waste Elimination by Method Study

Important point of waste elimination by method study

Eliminating Non-Value-Adding Activities
Method study involves breaking down each process into its component tasks. By identifying unnecessary movements, delays,
and redundant activities, non-value-adding steps can be removed. This streamlining reduces waste in time and resources.

Improving Layout and Material Flow

Through method study, the layout of workstations and the flow of materials can be optimized to minimize movement and
transportation waste. It ensures that the most efficient paths and layouts are used, reducing the time and energy spent moving
products or materials.

Standardizing Best Practices

By analyzing different methods of performing a task, method study can help identify the most efficient way to complete each
operation. Standardizing these best practices across the workforce leads to consistent performance, reducing errors and waste
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associated with variation.
Reducing Waiting Time
By examining the synchronization between different stages of the manufacturing process, method study can identify bottlenecks
and imbalances in production flow. Smoothing out these delays reduces waiting times, preventing idle time for workers or
machines.

Minimizing Defects and Rework

An important outcome of method study is the establishment of better work procedures, which can help reduce mistakes and
defective products. As a result, rework or scrap is minimized, leading to reduced material and labor waste

Improving Worker Productivity

By designing more efficient workflows, method study can help workers perform tasks with less effort. Ergonomic improvements
reduce physical strain, leading to fewer mistakes and increased productivity, thereby eliminating wasted time and energy.

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Optimizing Equipment Utilization
Method study can assess how equipment is being used and whether it is functioning optimally. Adjustments in
machine operations or maintenance schedules can reduce breakdowns or inefficient use of machinery, minimizing
downtime and waste.

Enhancing Inventory Management

Analyzing the flow of materials through method study allows for better control over inventory levels. Overstocking
and understocking can be avoided, reducing both material waste and the costs associated with storage or shortages.

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 Ergonomics in method study

Ergonomics : The word ergonomics comes from the Greek word “ergon” which means work
and “nomos” which means laws. It’s essentially the “laws of work” or “science of work”.
Good ergonomic design removes incompatibilities between the work and the worker and
creates the optimal work environment.

Ergonomics plays a crucial role in method study by focusing on optimizing human well-being
and overall system performance in work environments. The goal is to design tasks,
workspaces, tools, and equipment in a way that maximizes productivity while minimizing
discomfort, fatigue, and injury risks.
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Improving Task Efficiency
Ergonomics helps in analyzing tasks to eliminate unnecessary movements or awkward postures. This
streamlines work processes, making tasks easier and faster for workers to perform, leading to increased
efficiency and productivity.
Reducing Fatigue and Discomfort
By ensuring that workstations, tools, and equipment are ergonomically designed, workers can maintain
more natural and comfortable postures. This reduces physical strain and fatigue, allowing employees to
work more effectively for longer periods.
Enhancing Safety
Ergonomics identifies potential risks in work processes that could lead to injury, such as repetitive motions,
heavy lifting, or awkward positioning. Method study incorporates ergonomic principles to redesign these
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processes and minimize the risk of workplace injuries.
Increasing Job Satisfaction
Ergonomically designed workplaces improve worker comfort and well-being. When workers feel
comfortable, they are more likely to be satisfied with their jobs, leading to better morale and lower
absenteeism.
Supporting Workload Distribution
Ergonomics contributes to balancing workloads in a method study by ensuring that tasks are distributed in
ways that prevent overexertion and repetitive strain. This ensures that workers are not overloaded and can
perform their tasks effectively without burnout.
Promoting Effective Tool Design
Method study, when combined with ergonomics, focuses on designing or selecting tools that fit the physical
capabilities of workers. This reduces errors, improves precision, and ensures that tools are easy and safe to
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use.
 Identification of the operations or tasks that need method study

1. High Cost Operations

•Indicator: Operations or tasks that involve excessive costs, whether from labor, materials, or energy.
•Method Study: Identify tasks with high costs relative to the output or value they create. These tasks may require a method
study to reduce expenses by finding more efficient ways of performing the work.

2. High Rework or Defects

•Indicator: Tasks that frequently produce defective products or require rework.

•Method Study: Operations that lead to high error rates are ripe for method study. This study can uncover causes of defects

and propose changes to minimize errors and improve quality.

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3. Excessive Worker Fatigue or Discomfort
•Indicator: Tasks that lead to physical strain, fatigue, or discomfort for workers.
•Method Study : Fatigue reduces worker productivity and increases the risk of errors. A method study can assess ergonomic
factors and modify the process to reduce physical strain.

4. Unnecessary Movement or Transportation

•Indicator: Tasks that involve excessive walking, transporting materials, or unnecessary movements.
•Method Study : Method study can identify and eliminate unnecessary movement, optimizing the layout or procedures to
reduce travel time or wasted motion.

5. Inconsistent Task Performance

•Indicator: Significant variability in how different workers perform the same task, leading to inconsistent results.
•Method Study : Method study can standardize the task, ensuring that all workers follow the most efficient and effective
process, reducing variation in performance.
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 6. Long Task Duration
•Indicator: Tasks that consistently take longer than expected or desired.
•Method Study Trigger: Operations with long durations can benefit from method study to break down
the task into smaller steps and find ways to speed up the process without sacrificing quality.

7. Underutilization of Resources
•Indicator: Tasks where workers, machines, or materials are not fully utilized.
•Method Study: Method study can identify tasks where resources are underutilized, suggesting changes to
ensure optimal use of people, equipment, or materials.

8. Frequent Breakdowns or Maintenance Issues

•Indicator: Tasks involving equipment that frequently breaks down or requires regular maintenance.
•Method Study : Frequent equipment issues can signal the need for a method study to identify the root causes
and explore maintenance practices or operational improvements.
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 Lean Manufacturing

• Lean manufacturing is a methodology that focuses on minimizing waste within

manufacturing systems while simultaneously maximizing productivity. Waste is seen as

anything that customers do not believe adds value and are not willing to pay for. Some of

the benefits of lean manufacturing can include reduced lead times, reduced operating

costs and improved product quality.

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 How Lean principles can be applied to work study
• Integrating Lean Manufacturing principles into work study can significantly enhance operational

efficiency by streamlining processes, reducing waste, and optimizing human and material resources.
1. Value Stream Mapping (VSM)
•Work Study Application: Use VSM to identify value-added and non-value-added activities in the workflow. This
helps identify areas where time and effort can be reduced without affecting the final product or service quality.
2. Elimination of Waste (Muda)
•Work Study Application: Classify waste types (overproduction, waiting, defects, over-processing, motion,
inventory, and transportation) within each work study. Lean principles can direct attention to where waste is most
prevalent in tasks, and work study can analyze how to reduce or eliminate these wastes.
3. Standard Work
•Work Study Application: Lean promotes standard work procedures that ensure consistency and efficiency. Work
study can help create detailed time studies to establish the most efficient methods, which become part of the
standard process. 32
4. Kaizen (Continuous Improvement)

•Work Study Application: Encourage incremental improvements in the workplace. Work studies can

regularly analyze and re-evaluate processes to continuously seek improvement opportunities.

5. 5S Methodology

•Work Study Application: This methodology (Sort, Set in Order, Shine, Standardize, Sustain) is used in

Lean to organize the workplace. During work studies, incorporating 5S ensures that the workspace is

organized efficiently, reducing motion waste and making tasks faster and more intuitive.

6. Takt Time, Cycle Time, and Lead Time

•Work Study Application: Measure and balance the cycle time (the time taken to complete a task) and Takt

time (the rate at which products must be completed to meet demand). These Lean metrics can guide work
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study analysis to ensure that the production pace aligns with customer demand.
 Influence of psychological and social factors on outcomes of method study
Psychological Aspects
• Motivation
Motivation influences how committed and engaged employees are with the method study. Workers who feel their
contributions are valued and have a clear sense of purpose are more likely to embrace new methods and provide honest
feedback.
•Impact: High motivation leads to better cooperation, higher productivity, and a more accurate understanding of the
tasks being studied, ensuring successful implementation of new methods.

• Perception and Attitude

How workers perceive the purpose of the method study affects their cooperation. If they believe the study aims to
improve their work environment or efficiency, they are more likely to participate positively. However, if they view it as
a threat (e.g., job cuts or increased workload), they may resist or provide incomplete data.
•Impact: Positive attitudes lead to accurate data collection and smoother transition to new methods, while negative
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attitudes can result in resistance, errors, or incomplete cooperation.
 Stress and Fatigue
•Employees under stress or fatigue may struggle to perform optimally, which can distort the data collected during a
method study.
•Impact: High levels of stress or fatigue can lead to inaccurate time studies, errors in task performance, and resistance to
change, ultimately affecting the validity of the study results.

Social Aspect

Group Dynamics
The relationships and dynamics within a team influence how members cooperate with the study. If there is strong group
cohesion and trust, employees are more likely to support each other and share honest feedback.
•Impact: Positive group dynamics foster better communication, collaboration, and adaptation to new methods, while
negative dynamics (e.g., conflict, mistrust) can hinder the study's effectiveness.

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Cultural Norms and Values
•The prevailing organizational culture and social values shape how workers respond to method studies. In cultures that
emphasize collaboration and continuous improvement, employees may be more open to participating in the study.
Conversely, hierarchical or rigid cultures may foster resistance or lack of openness.
•Impact: A supportive culture enhances the quality of data gathered, while a rigid, hierarchical culture may lead to
resistance, inhibiting the successful implementation of new methods.

Communication and Feedback Channels

•Effective communication channels within the organization play a critical role in how the findings of the method study
are received and implemented. Transparent, two-way communication helps to alleviate concerns and fosters trust.
•Impact: Clear communication ensures that all stakeholders understand the benefits of the study, which promotes
cooperation. Poor communication can result in misinformation, misunderstandings, and resistance to the changes
proposed by the study. 36
 Importance of Pareto Analysis in Method Study

Pareto analysis is a decision-making technique used to identify the most significant factors
contributing to a problem or outcome. It's based on the Pareto Principle (80/20 rule), which
suggests that 80% of the effects come from 20% of the causes. In method studies, Pareto
analysis helps prioritize improvements by focusing on the areas with the greatest impact.

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Pareto Analysis Steps
1.Identify and List Problems. Write out a list of all of the problems that you need to resolve.
2.Identify the Root Cause of Each Problem.
3.Score Problems. Now, score each problem that you've listed by importance.
4.Group Problems Together.
5.Add up Scores for Each Group
6.Take Action.

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 Relevance of Pareto Analysis to Method Study

1. Prioritize Key Issues

Instead of addressing every inefficiency or defect equally, Pareto analysis allows you to focus on the most
significant factors first, where improvements will have the greatest impact. This prioritization ensures that
resources are used effectively.
2. Improve Efficiency
By focusing on the vital few causes that contribute to the majority of inefficiencies or problems, Pareto analysis
helps to streamline operations. This leads to better use of time and resources in a method study, driving faster
improvements.
3. Data-Driven Decision Making
Pareto analysis provides a clear, visual representation of where to focus improvement efforts based on data,
making the decision-making process more objective and evidence-based. It ensures that changes are made based
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on real-world impact rather than assumptions
4. Increase Worker Engagement
•When workers see that changes are being made to address the biggest pain points in their
process, they are more likely to support the changes. This boosts cooperation during a method
study and makes the implementation of improvements smoother.

5. Measure Progress
•Pareto analysis can be used both at the start and throughout a method study to track
improvements. It allows teams to measure how reducing or eliminating key issues affects
overall process performance, ensuring that the study is having the desired effect.

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 Method Study Integration with Six Sigma

• Method study can be effectively integrated with Six Sigma to improve process efficiency and quality by

reducing variation and eliminating defects.

• Six Sigma is a set of methodologies and tools used to improve business processes by reducing defects and

errors, minimizing variation, and increasing quality and efficiency. The goal of Six Sigma is to achieve a level

of quality that is nearly perfect, with only 3.4 defects per million opportunities. This is achieved by using a

structured approach called DMAIC (Define, Measure, Analyze, Improve, Control) to identify and eliminate

causes of variation and improve processes.

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 Method Study and Six Sigma: Key Areas of Integration

DMAIC Framework
Six Sigma’s core methodology is the DMAIC cycle (Define, Measure, Analyze, Improve, Control). Method study can
complement each of these phases by providing detailed insights into work processes and task performance.

•Define: Identify the project goals and key processes that need improvement.
• Integration: Method study helps define the specific tasks or work methods that are inefficient or prone to defects.
This is the foundation for selecting key areas to improve, such as reducing task time or eliminating unnecessary
movements.

•Measure: Collect data to understand the current state of the process.

• Integration: Method study tools like time and motion studies can measure how long each task takes, how much
variation exists, and where bottlenecks or inefficiencies lie. This provides detailed, task-level data that supports Six
Sigma’s emphasis on measurable outcomes.
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•Analyze: Identify the root causes of defects or inefficiencies.
•Integration: The detailed breakdown of tasks in method study helps Six Sigma teams identify the specific
activities causing defects or process variability. Combining this with Six Sigma tools like root cause analysis or
Fishbone Diagrams enables a thorough understanding of what drives inefficiencies.

Improve: Develop solutions to eliminate defects and improve process performance.

•Integration: Method study can be used to test new work methods or reorganize tasks in a way that reduces
defects and variability. By combining insights from method study with Six Sigma’s data analysis, teams can
implement process improvements that are both efficient and high in quality.

Control: Implement controls to sustain the improvements and ensure consistent performance.
•Integration: Once the process has been improved, method study can help standardize new work methods.
Standard operating procedures (SOPs) can be developed based on the optimized processes, and Six Sigma
tools like Statistical Process Control (SPC) can be used to monitor and control process performance over time.
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 Advantages of Method Study

• Work Simplification
• Improved working method
• Better Quality
• Improved work place layout
• Improved Equipment design
• Better Working Condition

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 Application of Method Study

• Improved designed of plant and equipment

• Improved use of material, plant, equipment and manpower
• Most effective handing of material
• Improved safety standards
• Productive and effective utilization of human effort

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Frequently asked questions ….

Q1. What are factors affecting production?

Q2. What is the need of Production Planning?
Q3. What is the cost and benefits of using PPC techniques ?
Q4. What Is The Meaning Of Production Planning?
Q5. What Does A Production Planner Do?
Q6. What Are The Strategies Taken Care By Production Planning?
Q7. What Are The Stages Of Production Planning & Control?

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 References
1. Samson Eilon, “Elements of production planning and control”, Universal Book
Corpn.1984
2. Elwood S. Buffa, and Rakesh K. Sarin, “Modern Production / Operations Management”,
8th Ed. John Wiley and Sons, 2000.
3. Kanishka Bedi, “ Production and Operations management”, Oxford university press,
2ndEdition 2007.
4. K. C. Jain& L.N. Aggarwal, “Production Planning Control and Industrial Management”,
Khanna Publishers, 1990.
5. https://www.google.com/search?q=production&source=lnms&tbm=isch&sa=X&ved=2a
hUKEwjg4eWj1ZLqAhVOH7cAHdC_AtIQ_AUoAnoECBUQBA&biw=1517&bih=730
6. https://kalyan-city.blogspot.com/2012/01/what-is-production-planning-meaning.html

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 Text Books / Reference Books

1. Elements of Production Planning and Control by Eilon Macmillan.

2. Elwood S. Buffa, Modern Production/Operations Management, Wiley
Series, 8th Edition.
3. Lee J. Krajewski, Operations Management, Prentice-Hall of India, New
Delhi, 6th Edition.
4. R.S. Parmar, Welding Technology, Khanna Publishers
5. R.K. Rajput, A Text book of Manufacturing Tech.( Laxmi Publications )

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Video/ Nptel Notes Links
https://www.youtube.com/watch?v=9qBZyzjoqAo&t=34s

https://www.youtube.com/watch?v=vA_8VqpNgb8

https://www.youtube.com/watch?v=4FdEz5aqwII&t=38s

https://nptel.ac.in/courses/112/107/112107143/

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 E-Books Links/ Study Material
Links/PPT Links
https://easyengineering.net/production-planning-and-control-jayakumar/

http://airwalkbooks.com/images/pdf/pdf_52_1.pdf

http://www.ddegjust.ac.in/2017/Uploads/11/POM-326.pdf

https://www.slideshare.net/sudhirpawar12/production-planning-control-ppt

https
://www.wisdomjobs.com/e-university/production-planning-and-control-inte
rview-questions.html 50
 Lecture Outcome / Summary
• Basic understanding of the need and benefits to use
Production Planning and control Systems

• Introduction of Important terms like inventory, quantity and

quality to the learner.

• Advantages/ Limitations of PPC

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Exercise for learners

Try to learn more about the Production Planning and Control systems
adopted in Multi National Companies.

Try to explore the reasons of success and failures of at least two

popular industries each as a case study.

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For any queries you
may contact me on:

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