A session on

INDUSTRIAL ENGINEERING
1
BY
SANDEEP PRASAD
M.F.TECH , NIFT , INDIA

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Work Study - Definition

2

Work Study is the systematic examination of the

methods of carrying out activities such as to improve

the effective use of resources and to set up standards
of performance for the activities carried out.

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Work Study and its tools

3

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Work
WORKSTUDY
Measurement

Method
Study

Best way to
do the job

Time it takes
to do the job

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Work Content (Total time of a job)

Basic
work
content
Total
time of
operatio
n under
existing
conditio
ns

Basic work content of product

and / or operation
5

Total
ineffecti
ve time

A : Work content added by poor

product design or materials utilizatio

B : Work content added by inefficient

methods of manufacturing or operation
(Poor layout, material handling, &WIP)

C :: Ineffective time resulting from

human resources contribution
(Absenteeism,poor workmanship,accidents

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Productivity is:
6

The Ratio between OUTPUT and

OUTPUT INPUT

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Productivity Caln.
7

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Factory Example
8

Factory 1

More
productive

Produced 500 dresses

per day with 50 operators

Therefore 1 operator
makes 10 dresses per day

The Productivity ratio is 1

person to 10 dresses

Factory 2

Produced 675 dresses per

day with 75 operators.

Therefore 1 operator
makes 9 dresses per day.

The Productivity ratio is 1

person to 9 dresses
Production

higher

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10

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Method Study - Definition

11

The systematic recording and critical examination of

ways of doing things in order to make improvements

is known as Method Study.
Founder : Frank Gilbreth
Developed further by : Professor Barnes.

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Method Study - Benefits

12

Better understanding of work performed

Improved operator performance
More safety & less risks from hazards for
and assets.
Less operator fatigue.

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health

Method Study - Steps

13

SREDDIM ( Pneumonic)
Select work to be studied
Record from observation of all relevant facts.
Examine critically(with help from your friends)
Develop the best method and workplace.
Define a new method which gives best economic returns.
Install a standard practice.
Maintain by regular routine checks.

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Work Measurement - Definition

14

Work Measurement is the application of techniques

& designs to establish the time for a qualified Worker

to carry out a task at a defined rate of working.

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Session 2
15

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Tools of Work Measurement

16

TRAAPU
Activity Sampling
Use of Cycle Checks
Rating
Allowances
Time Study
Production Study

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Tools of Work Measurement

17

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Tools of Work Measurement

Activity Sampling - A technique in which a large

18

number of observations are made over a period of

time of one group of machines, processes or
workers.
Cycle Checks

Pick
Align
Position
Sew
Dispose
Pick

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Tools of Work Measurement

- Time Study
19

Purpose of Time Study :

Establish Standard Times
Rate Operator performance
Gain information to calculate overall production capabilities
and Data for capacity planning.
Establish the total Work content of finished goods.

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Tools of Work Measurement(Contd.)

20

Types of Stop Watches :

Flyback watches

As the user presses the top knob , the clock hands return to zero
and begins timing for the next element.

Split hand watches

While one hand flies back when the top knob is pressed,the other
is stopped.After the second hand has been read,a side knob , on
the top left edge of the watch is pressed and this cause the stopped
hand to fly back to join back the other hand which has been
moving around the usual way.

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Session 3
21

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Allowances
22

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Rating / Basic Time/ Standard Time

23

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Standard Time Calcn.

24

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Determination of sample size of Cycle Checks

25

* For 95.45 confidence level and a margin of error of +/- 5 %

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Efficiency Calcn
26

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PMTS(Predetermined motion time systems) /MTM / GSD

27

PMTS : PMT Systems are methods of setting basic

times for doing basic human activities necessary for

carrying out a job or task.
MTM : ( Method Time Measurement)

It defines

eight hand movements , nine foot and trunk movements & two eye
movements
For each movement , a time value is assigned.

GSD (General Sewing Data)

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28

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Process chart symbol

OPERATION
Indicates the main steps in a process, method or procedure. Usually
29
the part, material or product
concerned is modified or charge

during the operation

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Process chart symbol

INSPECTION
Indicates an inspection for quality and / or check for quality
30

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Process chart symbol

TEMPORARY STORAGE OR DELAY
Indicates a delay in the sequence of events: for example, work
waiting between consecutive operations, or any object laid aside
31

temporarily without record until required

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Process chart symbol

TRANSPORTATION
Indicates the movement of workers, materials or equipment from
place to place

32

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Process chart symbol

PERMAMENT STORAGE
Indicates a controlled storage in which material is received into or
issued from a store under some
33 form of authorization, or an item is
retained for reference purposes

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Process chart symbol

COMBINED ACTIVITIES

When it is desired to show activities

performed at the same time or
34
by the same operative at the same workstation, the symbols for
those activities are combined, e.g. the circle within the square
represents a combined operation and inspection.

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Two-handed Process Chart

The two-handed process chart is a process chart in which the
activities of a workers hands (or limbs) are recorded in their
relationship to one another
35 chart is a specialized form of
The two-handed process

process chart because it shows the two hands (and

sometimes the feet) of the operators moving or static in
relation to one another, usually in relation to a time scale.
The advantage of incorporating a time scale in the chart
form is that the symbols for what the two hands are doing
at any given moment are brought opposite each other.

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Two-handed Process Chart

Generally used for repetitive operations, when one cycle
of the work is to be recorded. Recording is carried out in
more detail than is normal flow charts.
36

The symbols used has slightly different meaning :

1. Operation : Is used for the activities of grasp, position,
use, release, etc. of a tool, component or material.
2. Transport : Is used to represent the movement of the
hand (or limb) to or from the work, a tool or material.
3. Delay : Is used to denote time during which the hand or
limb being charted is idle (although the others may be in
use)
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Two-handed Process Chart

37

4 . H o l d : I s u s e d t o r e p re s e n t t h e a c t i v i t y o f
holding the work, a tool or material i.e, when the
hand being charted is holding something.
5. Inspection : examination of a piece.

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Two-handed Process Chart

T h e v e r y a c t o f m a k i n g t h e c h a r t e n a b l e s t h e w o r k

study man to gain an intimate knowledge of the

38

details of the job, and the chart itself enables him to

study each element of the job by itself and in
relation to other elements.
F r o m t h i s s t u d y i m p r o v e m e n t s i d e a s a r e d e v e l o p e d .
T h e s e i d e a s s h o u l d b e w r i t t e n d o w n i n c h a r t f o r m

when they occur.

T h e b e s t m e t h o d i s g e n e r a l l y t h a t w h i c h r e q u i r e s

the fewest movements.

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Two-handed Process Chart

39

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Two-handed Process Chart

EXAMINE critically
An examination of the details of the original method,
using

the

questioning

certain points.

technique,

at

once

raises

40

1)

Why is it necessary to hold the tube in the jig?

2)

Why cannot the tube be notched while it is being

rotated instead of the right hand having to wait?

3)

Why does the tube have to be taken out of the jig

to break it?

4)

Why pick up and put down the file at the end of

each cycle? Can it not be held?
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Two-handed Process Chart

41

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Two-handed Process Chart

42

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Two-handed Process Chart

Some points on compiling charts are worth mentioning :
Study the operation cycle a few times before starting to
record
43

Chart one hand at a time

Do not record more than a few symbols at a time
The action of picking up or grasping a fresh part at the
beginning of a cycle of work is a good point at which to
state the record.

Start with the hand that handles the part first or the
hand that does the most work.

The exact point of

starting is not really important, as the complete cycle

will eventually come round to it10/29/15
again, but the point

Procedure flow chart

44

Process charts can be used in the office but it is more useful to use
a variation of the process chart known as a procedure flowchart
this is in effect a document-type flow process chart, since it charts
the progress of a document or series of documents through a
procedure

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Symbols used in Procedure flow chart

Identify the
information

Start / End
45

Process Step

Decision

Connector

Identify the responsible

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Symbols used in Procedure flow chart

46

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String Diagram

47

The string diagram is a scale plan or model on which a thread is

used to trace and measure the path of workers, material or
equipment during a specified sequence of events.
One technique for recording and examining this form of
activity is the string diagram. It is one of the simplest of
the techniques of method study and one of the most
useful.
String diagram should be drawn correctly to scale.
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String Diagram
String diagram is a useful tool for recording the
distance traversed by a worker in the working area.
Construction of the diagram involves the following
steps:
S t e p 1 : P r e p a r i n g a s t 48
udy sheet.
The worker under consideration is followed and the different
points in the working areas he covers are noted down in a study
sheet.
The

recording of movements is continued till a representative

picture of the workers movements is obtained.

This

implies that the movements are noted down for enough

number of cycles so as to capture the actual work cycle in terms

of the journey made by the worker with their respective
frequencies.
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String Diagram
S t e p 2 :

Drawing a scale plan of the working area.

Once the study sheet is prepared, the next step is to

draw a scale plan of the working area.
49

Machines,

benches, stores and all other points at which calls

are made by the worker are drawn to the scale together with
doorways, pillars etc. that affect the paths of movements.
The

plan is then attached to a softwood or composition board

and pins are driven firmly at every stopping point.

The

heads of the pins are allowed to stay clear of the surface by

about 1cm. Pins are also driven in at all turning points on the
route.
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String Diagram
S T E P 3 : C o m b i n i n g S t e p s 1 a n d 2 t o c o n s t r u c t t h e

final diagram.
In

50
the final Step, a measured
length of thread is taken and

tied round the pin at the starting point of the movements.

It

is then led around the pins at the other points of call in the

order noted in the study sheet till all the movements as noted
in Step 1 have been covered .
The

resulting diagram is the string diagram.

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String Diagram
F

E
51

I
K

A
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String Diagram
I t s h o u l d b e a p p a r e n t t h a t t h e s t r i n g d i a g r a m i s

similar to the flow diagram. While one is used for

recording movements of materials, the other is used
for

recording

m o v e m52
ents

of

workers.

Most

often

these tools are used together-with the flow process

chart in order to give a better picture. The essential
difference between these two diagrams are:
a) It is necessary that the string diagrams be drawn
correctly to scale. The ordinary flow diagram can be
drawn

approximately

distances

marked

on

to
it

scale
so

with

that

unnecessary.
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important

scaling

off

is

String Diagram
b) A flow diagram would look bulky if too many to
and

fro

movements

between

different

points

are

there; however, such movements will not affect a

string diagram.

53

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String diagram
The examination of the diagram and the development of
the new layout can now proceed on the same lines as
with a flow diagram, with
54 templates being used and the
pins and templates can be preformed with a minimum
movement between them.
This can be ascertained by leading the thread around the
pins in their new positions, starting form the same point
and following the same sequence. When the thread has
been led around all the points covered by the study, the
length left over can again be measured.

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String diagram
T h e d i f f e r e n c e i n l e n g t h b e t w e e n t h i s a n d t h e t h r e a d

l e f t o v e r f r o m t h e o r i55
ginal study will represent the
reduction in distance traveled as a result of the
improved layout.
T h e p r o c e s s m a y h a v e t o b e r e p e a t e d s e v e r a l t i m e s

until the best possible layout (i.e. the layout with

which the minimum length of thread is used) is
achieved.

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Travel chart

56

.
A travel chart is a tabular record for presenting quantitative data
about the movements of workers, materials or equipment between
any number of places over any given period of time.

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Travel chart
Layout sketch of office showing location of
stations
6

5
3

57

1
7
10

8
9
Workstations
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Travel Chart

58

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Multiple activity chart

A multiple activity chart is a chart on which the activities of more
than one subject (worker, machine or item of equipment) are each
59

recorded on a common time scale to show their interrelationship

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Multiple activity chart

60

M u l t i p l e a c t i v i t y c h a r t i s a u s e f u l r e c o r d i n g t o o l

for situations where the work involves interactions of

different subjects. One or more workers looking after
different machines or a group of workers working on
loading materials at one point and dumping the same
at a different point are some examples where this
type of chart can be used effectively.

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Multiple activity chart

T h e f u n d a m e n t a l d i f f e r e n c e b e t w e e n t h i s t o o l a n d

the other charts described in the previous section are

as follows:

61

a) In multiple activity chart a time scale is used. No

such time scales are used in the charts described
earlier in this chapter.

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Multiple activity chart

b)

Multiple

activity

charts

can

be

used

equally

effectively even if there is no movement of workers

involved

in

the

work
62

under

consideration.

The

primary focus of this chart, for situations where the

workers are moving as a part of their work, is to
identify the idle time on the part of either the
workers or the machines. The focus of other charts
described so far were primarily to identify excess
distances traversed by the worker, which is only
indirectly related to the time.

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Multiple activity chart

T h i s i s u s e d w h e n i t i s n e c e s s a r y t o r e c o r d o n o n e

chart the activities of one subject in relation to

another.
B y

63

using separate vertical columns, or bars, to

represent the activates of different operatives or

machines against a common time scale, the chart
shows very clearly periods of idleness on the part of
an of the subjects during the process. A study of the
chart often makes it possible to rearrange these
activities so that such ineffective time is reduced .
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Multiple activity chart

64

T h e m u l t i p l e a c t i v i t y c h a r t i s e x t r e m e l y u s e f u l i n

organizing teams of operators on mass-production

work, and also on maintenance work when expensive
plant cannot be allowed to remain idle longer.
I t c a n a l s o b e u s e d t o d e t e r m i n e t h e n u m b e r o f

machines which an operator should be able to look

after.

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Multiple activity chart

Team work : Inspection of catalyst in a converter
(original)

65

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Multiple activity chart

Team work : Inspection of catalyst in a converter
(improved)

66

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Layout
67

The best layout of a factory depends on the following

factors :

The minimum length of route for mechanical transportation.

The machinery location.
The method of transportation.
The production system involved.
The type of garment being manufactured.
The shape of the building and the number of its floors.
Safety requirements eg. For fire exits etc.

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Layout(Contd.)
68

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Session 4
69

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Principles of Motion Economy

70

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Principles of Motion Economy(Contd.)

71

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72

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Session 5
73

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Garment Engineering
74

Definition :

Garment engineering is a questioning technique, it

questions each process/operation of the total work
content and by using innovative methods of
construction and technology so that we can reduce
the work content and increase profitability.

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Garment Engineering ( Contd.)

75

where should it begin?

It should start in the design cell, because if we do this

at the production stage its too late, garment
engineering directly affects the costing so it must be
done at the development stage.

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Garment Engineering ( Contd.)

76

Who should be involved?

Designers, Sample room manager, Industrial

Engineering department and production

management all of them should give their input from
cutting to finishing.

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Garment Engineering ( Contd.)

77

Steps for Garment Engineering - CRAAFT

1. CHOOSE the operation / process to be

studied by making sure it is worthwhile spending
time to improve it.
2. RECORD-every detail about the job, even if it
seems to have no effect on the method; sometimes
the most minor detail can make a huge difference
in the Garment Engineering process.

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Garment Engineering (Contd.)

78

3. ASSESS - all the details by asking WHY?

WHERE? WHAT? WHO?
4. ALTERNATIVES- Consider all the alternatives
available for improvement and DEVELOP the most
suitable.
5. FIT - best alternative and make sure it is
understood by all concerned.
6. TAKE CARE- of the new technique once it is
installed successfully by continually checking that it
is still being performed correctly.
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Session 6
79

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Garment Engineering(Contd.)
80

Key areas for analysis

1. Seam types Various seam types should be analysed and considered to

simplify/reduce the work.
2. Stitch types- Explore various options in terms of seam types what is
possible just by changing the seam type. For example replace lock stitches
by chain stitch in case of Multineedle seams.
3. Machine types- Optimum use of technology to maximize , look in to
machine type, bed shapes and automation thats possible.
4. Attachments Attachment can help immensely in simplifying and
reducing the work content, sometime operations can be combined using
attachments to increase line balancing efficiency.
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Garment Engineering (Contd.)

81

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Garment Engineering(Contd.)
82

5. Special work aids- Special work aids can be

designed to simplify/reduce the work content.

This is a Venturi Tube which is uses air pressure to pick up the

labels, so there is no fiddling around while picking up the labels.

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Garment Engineering ( Contd.)

83

6. Fabric consumption- Fabric being 70% of the garment

cost is vitally important to monitor and if the
engineering is done properly we can certainly expect to save
fabric or reduce consumptions.
7. Cutting- how should it be done- we do not have Tailors now,
we have operators instead and they should be
working with clippers in their hands
8. Finishing- Finishing is an area which is generally
overstaffed being the last link of the value chain all the
problems from the previous stages have to be sorted out here,
Garment Engineering can reduce considerable manpower from
this area.
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Some Examples of GE
84

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Qualities of a Work Study

officer
85

Minimum standard of education.

Should be given practical exposure
Should have an inventive mind.
Should be able to have good human
relations Sincerity and honesty.
Enthusiasm & Tactfulness
Interest in and sympathy with
people.
Good
appearance
with
Self
Confidence.
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Responsibilities of work study

Department
86

Standard times

Proper methods

Be familiar with
the latest
equipment

Garment
breakdowns and
operation
sequences

Performance and
discipline

Line balancing
and line
layouts

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Responsibilities of work study Department

87

All productivity
related issues.
Keep
management
informed .

Monitoring of
factory lost time.

Familiar with
productivity
systems

Garment
engineering.

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THANK
YOU
88

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