Method study in Production and Operation Management

Method study enables the industrial engineer to subject each operation to systematic analysis. The main purpose of method study is to eliminate the unnecessary operations and to achieve the best method of performing the operation. Method study is also called methods engineering or work design.

“Method study is the systematic recording and critical examination or existing and proposed ways or doing work as a means or developing and applying easier and more effective methods and reducing cost.”

Fundamentally method study involves the breakdown of an operation or procedure into its component elements and their systematic analysis. In carrying out the method study, the right attitude of mind is important. The method study man should have:

1. The desire and determination to produce results.
2. Ability to achieve results.
3. An understanding of the human factors involved.

Method study scope lies in improving work methods through process and operation analysis, such as:

1. Manufacturing operations and their sequence.
2. Workmen.
3. Materials, tools and gauges.
4. Layout of physical facilities and work station design.
5. Movement of men and material handling.
6. Work environment.

Objectives of Method Study
Method study is essentially concerned with finding better ways of doing things. It adds value and increases the efficiency by eliminating unnecessary operations, avoidable delays and other forms of waste. The improvement in efficiency is achieved through:

1. Improved layout and design of workplace.
2. Improved and efficient work procedures.
3. Effective utilization of men, machines and materials.
4. Improved design or specification of the final product.

The objectives of method study techniques are:

1. Present and analyze true facts concerning the situation.
2. To examine those facts critically.
3. To develop the best answer possible under given circumstances based on critical examination of facts.

Scope of Method Study
The scope of method study is not restricted to only manufacturing industries. Method study techniques can be applied effectively in service sector as well. It can be applied in offices, hospitals, banks and other service organizations. The areas to which method study can be applied successfully in manufacturing are:

1. To improve work methods and procedures.
2. To determine the best sequence of doing work.
3. To smoothen material flow with minimum of back tracking and to improve layout.
4. To improve the working conditions and hence to improve labor efficiency.
5. To reduce monotony in the work.
6. To improve plant utilization and material utilization.
7. Elimination of waste and unproductive operations.
8. To reduce the manufacturing costs through reducing cycle time of operations.

Steps or Procedure Involved in Methods Study
The basic approach to method study consists of the following eight steps. The detailed procedure for conducting the method study is shown in the following figure.

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.

Method study procedure



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.
9. CONSIDERATIONS FOR SELECTION OF METHOD STUDY

The job should be selected for the method study based upon the following considerations:

1. Economic aspect
2. Technical aspect, and
3. Human aspect.

1. Economic Aspects
   The method study involves cost and time. If sufficient returns are not attained, the whole exercise will go waste. Thus, the money spent should be justified by the savings from it. The following guidelines can be used for selecting a job:
   
   1. Bottleneck operations which are holding up other production operations.
   2. Operations involving excessive labor.
   3. Operations producing lot of scrap or defectives.
   4. Operations having poor utilization of resources.
   5. Backtracking of materials and excessive movement of materials.
2. Technical Aspects
   The method study man should be careful enough to select a job in which he has the technical knowledge and expertise. A person selecting a job in his area of expertise is going to do full justice.
   

   Other factors which favor selection in technical aspect are:

   1. Job having in consistent quality.
   2. Operations generating lot of scraps.
   3. Frequent complaints from workers regarding the job.
3. Human Considerations
   Method study means a change as it is going to affect the way in which the job is done presently and is not fully accepted by workman and the union. Human considerations play a vital role in method study. These are some of the situations where human aspect should be given due importance:
   
   1. Workers complaining about unnecessary and tiring work.
   2. More frequency of accidents.
   3. Inconsistent earning.

Recording Techniques for Method Study
The next step in basic procedure, after selecting the work to be studied is to record all facts relating to the existing method. In order that the activities selected for investigation may be visualized in their entirety and in order to improve them through subsequent critical examination, it is essential to have some means of placing on record all the necessary facts about the existing method. Records are very much useful to make before and after comparison to assess the effectiveness of the proposed improved method.

The recording techniques are designed to simplify and standardize the recording work. For this purpose charts and diagrams are used.

Method Study techniques

The method study techniques are explained below

Recording techniques for method study

CHARTS USED IN METHODS STUDY
This is the most popular method of recording the facts. The activities comprising the jobs are recorded using method study symbols. A great care is to be taken in preparing the charts so that the information it shows is easily understood and recognized. The following information should be given in the chart. These charts are used to measure the movement of operator or work (i.e., in motion study).

1. Adequate description of the activities.
2. Whether the charting is for present or proposed method.
3. Specific reference to when the activities will begin and end.
4. Time and distance scales used wherever necessary.
5. The date of charting and the name of the person who does charting.

Types of Charts
It can be broadly divided into (A) Macro motion charts and (B) Micro motion charts. 

MACRO MOTION CHARTS
Following four charts are used under this type:

1. Operation Process Chart
   
2. Flow Process Chart
   
3. Two Handed Process Chart
   
4. Multiple Activity Chart
   

Diagrams are of two types

1. FLOW DIAGRAM
   
2. STRING DIAGRAM
   

METHOD STUDY SYMBOLS

Process Chart
Distance in Symbol Process description meter