1. WORK STUDY HOW THE TOTAL TIME OF A JOB IS MADE UP (IE411)

2. 2 HOW THE TOTAL TIME OF A JOB IS MADE UP (Source:International Labour Office, Introduction to Work Study, third edition, page 14) COMPONENTS OF MANUFACTURING TIME The basic work content is the irreducible minimum time theoretically required to produce one unit of product. It assumes un- interrupted working. Work content added either by poor design or inefficient methods of manufacturing operations is called the excess work content.

3. 3 HOW THE TOTAL TIME OF A JOB IS MADE UP (Source:International Labour Office, Introduction to Work Study, third edition, page 15) REASONS FOR EXCESS WORK CONTENT (Defects in Design) A sheet metal part may be so designed that it has to be cut out and then riveted or welded instead of pressing in one pc. Lack of standardization may mean small batches which will be processed in slower general purpose machines. Unnecessary close tolerances will require extra machining. Material of poor quality will prevent high speed processing. Shafts with with very large and very small diameters designed in one piece is a good example.

4. 4 HOW THE TOTAL TIME OF A JOB IS MADE UP THEREFORE, THE FIRST STEP TOWARDS RAISING PRODUCTIVITY AND TO LOWER THE COST OF THE PRODUCT IS TO ELIMINATE ALL FEATURES IN ITS DESIGN THAT ARE LIKELY TO CAUSE EXCESS WORK CONTENT.

5. 5 HOW THE TOTAL TIME OF A JOB IS MADE UP (Source:International Labour Office, Introduction to Work Study, third edition, page 15) REASONS FOR EXCESS WORK CONTENT (Inefficient Methods) Wrong size or type of machine with lower output. Either the plant or machine is in bad condition or the process is not operating properly due to wrong feed, speed, temperature etc. Wrong hand or machine tools. Layout may cause excessive travel time and hence waste of time and effort. Working method of the operator may cause waste of time and effort. Such as searching for the tool, not reading the operation plan, inappropriate pace etc.

6. 6 HOW THE TOTAL TIME OF A JOB IS MADE UP (Source:International Labour Office, Introduction to Work Study, third edition, page 19) REASONS FOR INEFFECTIVE TIME (Shortcomings of mngmnt.) Caused by unnecessary large product mix as a result of marketing policy leading to short runs for each type of product and machines stay idle because of excessive too many change overs. Has same effects as the previous one : short batch runs and high idle time. Causes stoppages of work leading to loss of mach hours, man hours and material waste. One order does not immediately follow the previous one leading to intermittent employment of plant and labor. Failing to ensure continuous supply of materials, tools and other equipment causes idle time. Without good maintenance policy and associated plans, equipment and man power, breakdowns are inevitable. Operating a machine or equipment which is not maintained well will cause high rate of scraps & reworks. Failing to provide appropriate working conditions will cause lack of safety and physical wearout of man power. Lack of safety and overloading man power will cause accidents which will result in losses of time and absence.

7. 7 HOW THE TOTAL TIME OF A JOB IS MADE UP (Source:International Labour Office, Introduction to Work Study, third edition, page 19) REASONS FOR INEFFECTIVE TIME (The Worker) Includes lateness, failing to start work immediately after “clocking in”, idling at work and deliberately working slowly. Careless workmanship causes rework or scrap or even a machine breakdown. Rework or scrap means that work has to be done again which means waste of time and material. Frailure to obey the safety regulations.

8. 8 HOW THE TOTAL TIME OF A JOB IS MADE UP IN GENERAL, FAR MORE INEFFECTIVE TIME IS DUE TO MANAGEMENT SHORTCOMINGS THAN TO CAUSES WITHIN THE CONTROL OF WORKERS.

9. 9 REDUCING THE WORK CONTENT AND INEFFECTIVE TIME Reducing the work content due to the product This type of excess work content may arise due to several reasons such as ;  Machine part designers are not familiar enough with production processes,  Architects are not familiar enough with construction, mechanical or electrical engineering subjects,  Customers may request close tolerances when it is not actually required neither by the form, function or fit of the product.  Designing a hole which is practically very difficult to drill.  Requesting chrome plating of a surface which is subject to physical wareout during the use of the product.  Selelection of wrong material either for product or for the required machine tool for material removal etc. Example 11 : Design problems

10. 10 REDUCING THE WORK CONTENT AND INEFFECTIVE TIME Reducing the work content due to process or method  process research and planning  proper maintenance procedures  method study  operator training Elimination of waste is achieved by means of,

11. 11 REDUCING THE WORK CONTENT AND INEFFECTIVE TIME Reducing ineffective time On the part of Management On the part of Workers

12. 12 REDUCING THE WORK CONTENT AND INEFFECTIVE TIME Concurrent Engineering (Designers, Production Staff and Quality People work together) Product development and value analysis Specialization & standardization Process planning Method Study/Design Operator trainig (both on job & safety) reduced product mix (standardization) increased batch sizes (speed) correct process flow & selection of mach/equipment/tools correct quality standards Review of quality standards should be geared to requirements, should not be higher than necessary, should not be neglected, should be consistent When You Produce Products Designed by Your Company Market and Consumer research (Demand by market & consumer needs) Product research (Technical requirements of the product) Pilot Production SERIAL PRODUCTION Product Data Management Sys (PDM) Production Data Mngm Sys