WORK MEASUREMENT

In this chapter, time is the major discussion. It involves in determining the time that a qualified worker should take to complete a job under normal working conditions. Time represents by labor standard, standard time and allowances allocate to workers in operation activities.

Work measurement concerns with determining the length of time should be taken to finish a job.

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Capacity Planning - Regular hours to used to produce one unit of product Human workforce requirements - Number of workers to hire by company Schedule the labor hours required to complete a job - The numbers of work follow the work schedule Evaluate proposed work improvement - Evaluate work before and after standard time Designing incentive system - Piece rate plan in a scheme, who can produce more output in the given time

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Appropriate for short and repetitive tasks Used to develop standard time

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Choose the job to study Inform involved workers Break the job into recognisable units Determine the number of cycles to observe/ how many times to observe 5. Time each elements, record the time and rate the workers performance 6. Compute the standard time

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Average Observed Time (AOT) - average time a wkr took to work on individual task from the start to finish Normal Time (NT) or Basic Time (BT) - time taken to complete a job while working under normal condition Standard Time (ST) - Average time for a job after adding allowances to the NT or BT

= Sum of All Times Number of cycle Or

Sum of All Times (*Number of cycles)(**Frequency)

* Omit any inconsistent or unusual data ** Frequency of Occurance

Tasks X Y

Observed time (minutes) 5 7 6 9 18 11

1- To calculate average observed time: Average observed time = sum of time recorded to performed for each element Number of observations a) Average observed time X = (5+6) 2 = 5.5 minutes (Ignore abnormal times & extremes values (high or low) because it represent erroneous during observation) b) Average observed time Y = (7 + 9 + 11) 3 = 9 minutes

Tasks A B C

Observed time (minutes) 3 2 9 5 4 10 7 11 20

1) Calculate average observed time for task A, B and C

Time taken to complete a job while working under normal condition NT = (AOT) (Performance Rating)

Tasks X Y

Observed time (minutes) 5.5 9

Observed Rate (rating) 110% 95%

To calculate normal time/basic time: Normal time/basic time X = (5.5 x 110) 100 = 6.05 minutes Normal time/basic time Y = (9 x 95) 100 = 8.55 minutes Total for normal time/basic time X & Y = 14.6 minutes

Tasks A B

Observed Rate (rating) 110% 115%

Observed time (minutes)

Normal time (minutes)

90%

1) Calculate normal time/basic time

Average time for a job after adding allowances to the NT or BT ST = (NT) ( 1 + *Allowance Factor) * Two ways of giving AF: 1. In %, e.g: 10% 2. In the amount of time, e.g: 12 mins per hour or 12 mins per day

Tasks

Normal Time or basic time (minutes) 6.05 8.55

Allowances: (8 hours per day)

Machine warming up = 15 minutes

Area clean up = 21 minutes Personal time = 60 minutes

X Y

To calculate standard times: First we need to identify the allowance that need to be in percentage value. Allowances = Non-work time x 100 Total time = (15+21+60) x 100 8 x 60 = 20% Standard time = Total basic time x (1 + Allowances) = 14.6 x (1+0.2) = 17.52 minutes

Tasks

Normal Time or basic time (minutes)

6.05 8.55

Allowances: (8 hours per day)

Machine warming up = 15 minutes Area clean up = 20 minutes Personal time = 50 minutes Unavoidable breakdown = 10 minutes

X Y

1) Calculate the standard time

It functioned to help to improve performance and their productivity level by continue to perform outstanding result according to standard. There are 4 types of allowances;. There are:

1. Relaxation Allowance The extra time in % given to workers to take a short break to overcome mental or physical fatigue. It includes nature calls, drinking, stretching, resting, etc

2. Contingency Allowance The extra time in % given to workers for unexpected situation occurance. For example, repairing minor defects on equipments or as simple as to pick a dropped tool(s).

3. Process Allowance The extra time in % given to workers due to natural delay in the process. For example, waiting for a crane to come, computers to respond, automated machines to be set up and etc .

4. Policy Allowance The extra time in % given to workers due to labour regulations or union agreement. For example, allowing muslims to perform their prayers and etc .

A work operation consisting of three elements has been subjected to a stop-watch study. The observations recorded are shown below.

Job Element A B C

Cycle Observation (Minutes) 1 2 3 4 0.5 0.3 0.2 0.2 0.8 0.6 0.6 0.7 0.5 0.4 0.6 0.4

Performance Rating 110% 90% 80%

The workers work 26 days in a month. The allowance time for the operation based on 8 hour-work-day are as follows: Relaxation Process = = 30 minutes/day 18 minutes/dayr

Requirements (Show all workings): 1. Calculate the basic or normal time for all jobs elements. 2. Determine the standard time of the work operation. 3. What is the maximum number of output that can be produced per day? 4. If monthly demand for the product is 10,000, can the production capacity meet the demand by just operating 8 hours per day? 5. Determine the additional number of operating hours per month to be able to produce 10,000 products.

Job Element A B

Average Observed Time (Minutes)

AOT x RF

Normal Time 0.3300 0.6075

(0.5 + 0.3 + 0.2 + 0.2) / 4 0.300 x 1.1 = 0.300 (0.8 + 0.6 + 0.6 + 0.7) / 4 0.675 x 0.9 = 0.675

(0.5 + 0.4 + 0.6 + 0.4) / 4 0.475 = 0.475 x 0.8

Total Normal Time

0.3800
1.3175

Allowance time = (30 mins/day) + (18 mins/day) = 48 minutes per day (8hrs x 60 mins) per day = 0.10 @ 10% Standard time = NT (1 + Allowance Factor) = 1.3175 minutes (1 + 0.10) = 1.4493 @ 1.45 minutes per unit

Maximum output per day = 480 minutes / 1.45 mins per unit = 331.03@ 331 units/day

Output per month

= 331 units x 26 days = 8606 units per month

Production capacity Cannot meet the demand

Shortage unit = (10,000 8,606) units = 1,394 units Additional hours required = 1,394 units x 1.45 minutes/unit = 2,021.3 mins 60 mins = 33.7 hours

Apr 2011 (B2) Oct 2010 (A5) Apr 2010 (B4) Oct 2009 (A4) Apr 2009 (Nil) Oct 2008 (B4) Apr 2008 (Nil) Oct 2007 (A2, B5) Apr 2007 (B3)