3.

i
An Introduction to
Industrial Engineering and
Work Study
 Industrial
3.i.A

Engineering
 Productivity improvement through :
 Work Study
 Method Study
 Work Measurement
 Fixing Standard time
 Work Sampling
 O&M
 Plant Layout & Material Handling
 Value Analysis & Value Engineering
 Quality Control
 Statistical Process Control
 Problem Solving Techniques

Source: Study material on Industrial Engineering-II, By Andhra Pradesh Productivity Council,

Chp. No.1 to 4, From Pg No. 1 to 32.
 Work Study
METHOD STUDY

TO SIMPLIFY THE JOB

AND
DEVELOP MORE
ECONOMICAL
METHODS OF DOING IT

WORK
STUDY
WORK MEASUREMENT

TO DETERMINE HOW
LONG IT SHOULD TAKE
TO CARRY OUT

HIGHER
PRODUCTIVITY
 Productivity Concepts
 Continuous efforts are put up for improving the Utilization of
resources. This needs defining appropriate measures of
performance.

The Ratio of output produced to the input

resources utilized in the production
 Input resources in any Productive System are :
- Land
- Material
- Machines
- Men
 Productivity Concepts
 Total Productivity = Aggregate Output
Aggregate input

 Partial Productivity = Aggregate output

Any single input

 Productivity Measurement =
 National Level MACRO
 Industry Level MACRO

 Express output and input in Monetary terms

 Labour Productivity = Output per worker

 Benefits of Higher
Productivity
 More output with same or lesser input.
 Same output is produced with lesser input.
 More output with more input but proportional output
is more being more than the increase in input.
 Financial Measure :
 Total output = cost of Product sold

 Total expenses (input) = cost of goods produced

 Productivity = sales / cost of sales

 Profit = sales – Cost of Sales

 Benefits of Higher
Productivity
Return on Investment Profit
------------------------------- = ---------------------
A measure of Productivity Total Investment

 Productivity of materials
 Productivity of Land – Buildings
 Productivity of Labour
 Factors Contributing To
Productivity Improvement
 Time required to produce one unit of an output. (Man
Hours)
 Variation in standard – Actual inputs – (Machine Hours)
 Contributing Factors :
 Design aspects
 Standardization
 Quality Standards
 Productive Machines
 Operating Conditions

Contd…
 Factors Contributing To
Productivity Improvement
 Interaction between men & machines
 Working methods of operatives

Proper planning of the above will help improving productivity.

 Operational Inefficiencies arise out of
 Improper planning of work

 Improper maintenance of machines

 Carelessness & negligence of workers

 Factors important in raising productivity

 Mangerial efficiency

 Operative efficiency
 Role of Management in
coordinating resources of
an enterprises
Techniques For Productivity
Improvement
 Work Content and Ineffective Time
 Reduce work content

 Reduce Ineffective Time

1. Basic Work Content is the irreducible minimum

time theoretically required to produce one unit of
output
2. Total work Content = Basic work content
+ Excess Time
Techniques For Productivity
Improvement
3. Excess Time = Time due to defects in design
or
Specifications of the product
+
Time due to inefficient methods
of manufacture

 Ineffective time is the time for which the worker or the machine
or both are idle due to the short comings of the management or
the worker
Work Contents And Ineffective
Time
Basic Work Content
Of Product
and / or operation

TOTAL
WORK
CONTENT Work Content Added
By defects in product or
Specifications of product
TOTAL
TIME
OF Work Content Added
OPERATION By inefficient methods of
UNDER Manufacture or operation
EXISTING
CONDITIONS

In efficient Time
Due to short coming
Of the management
TOTAL
INEFFECTIVE
TIME
Ineffective Time
With in the control
Of the worker
Work Content Due To Product
And BASIC
WORK
CONTENT
TOTAL
WORK
CONTENT
OF THE
PRODUCT
Process
A.1. Bad Design Of Product
Prevent use of most economic process WORK CONTENT ADDED
A.2. Lack Of Standardization By defects in design or
Prevent use of high production process specification of the
TOTAL
WORK A.3. Incorrect Quality Standards products
CONTENT Cause Unnecessary Work

B.1. Wrong Machine

Used
B.2. Process Not Operated Correctly
Or in bad conditions
WORK CONTENT ADDED
B.3. Wrong Tools
By inefficient methods of
Used
Manufacture or
B.4. Bad Layout operations
Causing Wasted Movement
B.5. Operative’s Bad
Working Methods

INEFFECTIVE
TIME
 Ineffective Time Due To
Shortcomings On The Part Of
Management And Workers
BASIC
WORK CONTENT

EXCESS

C.1. Excessive Product Variety

Adds idle time due to short runs

TIME OF OPERATION C.2. Lack Of Standardization

WITHIN THE Adds idle time due to short runs
CONTROL OF THE C.3. Design Changes
MANAGEMENT Add ineffective time due to stoppages and rework
C.4. Bad Planning
of work and order adds idle time of men and
machines
C.5. Lack of raw Materials
TOTAL TIME OF due to bad planning adds idle time of men and INEFFECTIVE TIME
machines
OPERATION Due to shortcomings
C.6. Plant Breakdowns of the
UNDER add idle time of men and machines
EXISTING management
CONDITIONS C.7. Plant In Bad Condition
adds ineffective time due to scrap and rework0
C.8. Bad Working Conditions
Add ineffective time through forcing workers to rest
C.9. Accidents
Add ineffective time through stoppages and
absence

D.1. Absence, Lateness and Idleness

Add ineffective time
INEFFECTIVE TIME
D.2. Careless Workmanship
Adds ineffective time due to scrap and rework With in the control
of the worker
D.3. Accidents
Adds ineffective time through stoppages and
absence
How Management Techniques Can
Reduce TOTAL
WORK
Work =
BASIC
WORK
BASIC
WORK

Content
CONTENT CONTENT CONTENT
TOTAL

A.1. Product Development And Value Analysis

reduce excess work content due to design defects
A.2. Specialization And Standardization
E L I M I N A T E

enable high production process to be used

A.3. Market Consumer And Product Research
ensure correct quality standards
Excess A.4. Product Development And Value Analysis
Work content
reduce excess work content due to excess material
totally
Eliminated B.1. Process Planning
if all ensure collection of correct machines
Techniques B.2. Process Planning And Research
applied
ensure correct operation of process
B.3. Process Planning And Method Study
ensure correct selection of tools
B.4. Method Study
ensure correct operation of process
D

B.5. Method Study And Operator Training

reduce work content due to bad working methods

TIME Ineffective Time

(to be eliminated)
How Management Techniques Can
ReduceWork
TOTAL = BASIC
BASIC
WORK

Content
TIME WORK CONTENT
IF ALL CONTENT nt
TECHNIQUES nt e
PERFECTLY o
C te d
r k
APPLIED
C.1. Marketing And Specialization wo i na
e ss elim
reduce idle time due to product variety c
C.2. Standardization
Ex eady
idle time due to short runs Alr
C.3. Product Development
reduces ineffective time due to changes in design
C.4.Production Control based on work measurement
Ineffective Time reduce idle time due to bad planning
Totally Eliminated C.5.Material Control
if all Techniques
Perfectly applied
Reduces idle time due to lack of raw materials
C.6. Maintenance – reduces idle time of men and
machines due to breakdowns
C.7. Maintenance – reduces ineffective time due to
plant in bad condition
C.8. Improved Working Conditions
enables workers to work steadily
C.9. Safety
measures reduce ineffective time due to accidents
D.1. Sound Personal Policies and Incentives
reduce ineffective time due to absence, e.t.c
D.2.Personal Policy And Operator Training
reduce ineffective time due to carelessness
D.3. Safety Training
reduces ineffective time due to accidents
 3.i.B Work Study

 Work Study = Time and Motion Study

 A scientific approach to study all forms of work with a view
to increase productivity.
 Work Study is a generic term for those techniques,
particularly method study and work measurement, which are
used in the examination of human work in all its contexts,
and which lead systematically to the investigation of all the
factors which affect the efficiency and economy of the
situation being reviewed, in order to effect improvement.
 Work study generally helps in improving productivity
without any major investment
 3.i.B Work Measurement
 Work measurement is the application of techniques
designed to establish the time for a qualified worker to
carry out a specified job at a defined level of performance

 Work measurement is concerned with investigation and

reduction of any ineffective time and subsequent
establishment of time standards for the operation when
carried out in the improved fashion, only after method
study has been conducted.
 3.ii 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.

Method Study is concerned in the

reduction of work content.
3.ii.A Basic Procedure To Conduct
Work Study
 Select : Select the job to be studied

 Examine : Examine the recorded facts critically and challenge

everything that is done considering the purpose & place where
it is performed, the sequence, the person doing and the means
by which it is done

 Develop – Develop the most economic method taking into

account and circumstances.

 Measure – Measure the quantity of work involved in the

method selected and calculate the standard time for doing it.
Basic Procedure To Conduct Work
Study…
 Define – Define the new method and the related time so that it
can always be identified.

 Install – Install the new method as agreed standard practice

with the time allowed.

 Maintain – Maintain the new Standard Practice by proper

control procedure.
 Important Pre Requisites
In Conducting Work Study
Good relations between Management and
workers

Good working conditions and environment

Workers to have confidence in the sincerity of

Management

Good Human relations and working Conditions.

 Direct Means of Raising Productivity
TYPE OF MEANS COST HOW EXTENT THE ROLE
CH

IMPROVE- QUICKLY OF OF WORK

OA

CAN IMPROVE
MENT STUDY
PR

RESULTS MENT IN
AP

BE PRODUCTI
ACHIEVED VITY

1.Development of Basic High Generally No Obvious Method Study

INVESTMENT

new basic research Years Limit to improve

process or Applied ease of
fundamental research operation and
improvement of Pilot plant maintenance
existing ones at design
stage
CAPITAL

2. Install more Purchase High Immeditly No Obvious Method study

modern or After Limit in plant layout
Process and to
higher – Installation
Research improve ease
capacity plant of operation
or equipment when
or modernise modernising
existing plant
 Direct Means of Raising Productivity
TYPE OF COST HOW QUICKLY EXTENT OF THE ROLE OF
CH

IMPROVEMENT MEANS CAN RESULTS IMPROVEMENT IN WORK STUDY

BE ACHIEVED PRODUCTIVITY
OA
PR
AP

3.Reduce the Product Not high Generally Limited – of the Method Study
work content of research compar-ed months same order as (and its
the product Product with 1 and that to be extension,
BETTER MANAGEMEN

development 2 expected from 4 value

& 5 . Should analysis) to
Quality mgmt.
precede action improve
Method Study under those design for
Value Analysis heads. ease of
production

4.Reduce the Process Low Immediate Limited, but often Method Study
work content of research of a high order to reduce
the process Pilot plant wasted effort
and time in
Process
operating the
planning
process by
Method Study
T

eliminating
Operator unnecessary
training movement
Value Analysis
 Direct Means of Raising Productivity
CH

TYPE OF COST HOW QUICKLY EXTENT OF THE ROLE OF WORK

IMPROVEMENT CAN RESULTS IMPROVEMENT STUDY
OA

MEANS
BE ACHIEVED IN
PR

PRODUCTIVITY
AP

5. Reduce LOW May start Limited, but Work measurement

ineffective slowly but often of a high to investigate
time (whether effect grows order existing practice.
BETTER MANAGEME

due to quickly Locate ineffective

management time and set
or to workers) standards of
performance as a
basis for –
A. Planning and
Control
B. Utilisation of
plant.
C. Labour cost
control
D. Incentive
NT

schemes
 Human Factors In The Application
Of Work Study

Evaluation of Human Performance

Involvement of workers – supervisor – work study -
man and management and their respective roles.
Work study man to have experience, personal
qualities, sincerity and honesty, enthusiasm, interest
and sympathy with people, tact, good appearance and
self confidence, ability to convince.