Industrial

Engineering
Direct Time Study

References:
1. Mikell P. Groover (2014) Work Systems and the Methods, Measurement, and Management of Work.1st
Edition, Pearson.
2. Benjamin W. Niebel (1993) Motion and Time Study. 9th Edition, Irwin
3. Stevenson, W.J., and Chong, S.C. (2014),Operation Management, 2nd Edition. Mc Graw Hill.
4. Jay Heizer, and Barry Render (2014), Operations Management: Sustainability and Supply Chain
Management. Pearson

Nor Akramin Mohamad

Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
 Direct Time Study
Sections:
1. Direct Time Study Procedure
Chapter 1.2 2. Number of Work Cycles to be Timed
3. Performance Rating
4. Time Study Equipment
 Direct Time Study - Defined
 Direct and continuous observation of a task
using a stopwatch or other timekeeping device
to record the time taken to accomplish the task
 While observing and recording the time, an
appraisal of the worker’s performance level is
made to obtain the normal time for the task
 The data are then used to compute a standard
time for the task
 Direct Time Study Procedure
1. Define and document the standard method
2. Divide the task into work elements
3. Time the work elements to obtain the
observed time Tobs
4. Evaluate worker’s pace relative to standard
performance to obtain normal time Tn
 Called performance rating (PR)
Tn = Tobs(PR)
5. Apply allowance factor to compute standard
time
Tstd = Tn(1 + Apfd)
 Document the Standard Method
 Determine the “one best method”
 Seek worker’s advice if possible
 Documentation should include:
 All of the steps in the method
 Special tools, gauges, equipment and
equipment settings (e.g., feeds and speeds)
if applicable
 Irregular elements and their frequency
 Once the standard method is defined, it should
not be possible for the operator to make further
improvements
 13.1

Form to document
the standard
method
 Why Documentation is Important
 Batch production – repeat orders after a
significant time lapse
 Methods improvements by operator – to
restudy task, must be able to prove a change
has occurred
 Disputes about method – operator complains
that standard is too tight
 Is operator using the standard method?
 Data for standard data system – good
documentation is essential for developing a
standard data system
 Divide Task into Work Elements
Guidelines:
 Each work element should consist of a logical
group of motion elements
 Beginning point of one element should be the
end point of the preceding element
 Each element should have a readily identifiable
end point
 Work elements should not be too long nor too
short
 Separate irregular elements, machine
elements, internal elements
 Time the Work Elements
 Each element should be timed over several
work cycles to obtain a reliable average
 Stopwatch timing methods:
1. Snapback timing method – stopwatch is
reset to zero at the start of each work
element
2. Continuous timing method – stopwatch is
allowed to run continuously throughout the
duration of the work cycle
Advantages of Each Timing Method
 Advantages of snapback method:
 Analyst can readily see how element times
vary from cycle to cycle
 No subtraction necessary to obtain
individual element times
 Advantages of continuous method:
 Elements cannot be omitted by mistake
 Regular and irregular elements can be more
readily distinguished
 Manipulation and resetting of the stopwatch
is reduced
 Performance Rating
Analyst judges the performance or pace of the
worker relative to the definition of standard
performance used by the organization
 Standard performance PR = 100%
 Slower pace than standard PR < 100%
 Faster pace than standard PR > 100%
 Normal time Tn = Tobs(PR)
 13.2

Direct time study

form
 Apply Allowances
 A PFD allowance is added to the normal time
to compute the standard time
Tstd = Tn(1 + Apfd)
where Apfd = allowance factor for personal time,
fatigue, and delays
 The function of the allowance factor is to inflate
the value of standard time in order to account
for the various reasons why the worker loses
time during the shift
 Rest Allowances

 Personal time allowance

 4% - 7% of total time for use of restroom, water
fountain, etc.
 Fatigue allowance
 Based on our knowledge of human energy
expenditure
 Delay allowance
 Based upon actual delays that occur
 Rest Allowances

1. Constant allowance
(A) Personal allowance ……………... 5
(B) Basic fatigue allowance ………… 4
2. Variable allowances:
(A) Standing allowance ……………… 2
(B) Abnormal position
(i) Awkward (bending) ………… 2
(ii) Very awkward (lying,
stretching) …………………… 7
 Rest Allowances

(C) Use of force or muscular energy in lifting, pulling,

pushing
Weight lifted (pounds)
20 …………………………………… 3
40……………………………………. 9
60……………………………………. 17
(D) Bad light:
(i) Well below recommended…. 2
(ii) Quite inadequate……………. 5
(E) Atmospheric conditions
(heat and humidity) …………… 0-10
 Rest Allowances
(F) Close attention:
(i) Fine or exacting……………….. 2
(ii) Very fine or very exacting…… 5
(G) Noise level:
(i) Intermittent—loud…………….. 2
(ii) Intermittent—very loud
or high-pitched………………... 5
(H) Mental strain:
(i) Complex or wide span
of attention.…………………….. 4
(ii) Very complex………………….. 8
(I) Tediousness:
(i) Tedious…………..……………… 2
(ii) Very tedious.…………………… 5
 Formula

1. Compute average observed time

Sum of the times recorded to

Average perform each element
observed =
time Number of observations

2. Determine performance rating and normal time

Average
Performance
Normal time = observed x rating factor
time

Normal time Tn = Tobs(PR)

 Time Studies

Add the normal times for each element to develop the

total normal time for the task
3. Compute the standard time

Standard time = Total normal time x (1 + Allowance factor)

Tstd = Tn (1 + Apfd)
or
Total normal time
Standard time =
1 - Allowance factor
This formula used if allowances are based on a percentage of the
time worked (i.e., the workday)
 Time Study Example 1
Average observed time = 4.0 minutes
Worker rating = 85%
Allowance factor = 13%

Normal time = (Average observed time) x (Rating factor)

= (4.0)(.85)
= 3.4 minutes

Standard time = Total normal time x (1 + Allowance factor)

= (3.4)(1 + 0.13)
= 3.842 minutes
 Time Study Example 2
Allowance factor = 15%
Cycle Observed (in minutes)
Performance
Job Element 1 2 3 4 5 Rating
(A) Compose and type letter 8 10 9 21* 11 120%
(B) Type envelope address 2 3 2 1 3 105%
(C) Stamp, seal, and sort 2 1 5* 2 1 110%

1. Delete unusual or nonrecurring observations (marked with *)

2. Compute average times for each element
Average time for A = (8 + 10 + 9 + 11)/4 = 9.5 minutes
Average time for B = (2 + 3 + 2 + 1 + 3)/5 = 2.2 minutes
Average time for C = (2 + 1 + 2 + 1)/4 = 1.5 minutes
 Time Study Example 2

3. Compute the normal time for each element

Normal time Tn = Tobs(PR)

Normal time for A = (9.5)(1.2) = 11.4 minutes

Normal time for B = (2.2)(1.05) = 2.31 minutes
Normal time for C = (1.5)(1.10) = 1.65 minutes

4. Add the normal times to find the total normal time

Total normal time = 11.40 + 2.31 + 1.65 = 15.36 minutes

 Time Study Example 2

5. Compute the standard time for the job

Tstd = Tn (1 + Apfd)

Tstd = 15.36 (1 + 0.15) = 17.66 minutes

or
Total normal time
Standard time =
1 - Allowance factor

15.36
= = 18.07 minutes
1 - .15
 Time Study Example 3
A process at a watch assembly plant has been changed. The
process is divided into three work elements. A time study has
been performed with the following results and the allowance for
the whole process is 18 percent of the total normal time.The
time standard for process previously was 14.5 minutes. Based
on the new time study, analyse whether the time standard
should be revised.

Average
Obs 1 Obs 2 Obs 3 Obs 4 PR
(min)

Element 1 2.60 2.34 3.12 2.86 2.730 1.0

Element 2 4.94 4.78 5.10 4.68 4.875 1.1

Element 3 2.18 1.98 2.13 2.25 2.135 0.9

 Time Study Example 3
 The normal time for an element in the table is its average
time, multiplied by the PR.
 The total normal time for the whole process is the sum of the
normal times for the three elements, or 10.01 minutes. To get
the standard time (ST) for the process, just add in the
allowance
Average (min) PR Normal Time

Element 1 2.730 1.0 2.730

Element 2 4.875 1.1 5.363

Element 3 2.135 0.9 1.922
Total Normal Time = 10.015

ST = 10.015(1 + 0.18) = 11.82 minutes/watch

Yes, change the time standard from 14.5 minutes to 11.82 minutes.
 Time Study Example 4
A direct time study was taken on a manual work
element using the snapback method. The regular
cycle consisted of three elements, a, b, and c.
Element d is an irregular element performed
every five cycles.
Work element a b c d
Observed time (min) 0.56 0.25 0.50 1.10
Performance rating 100% 80% 110% 100%

Determine the standard time for the work with

allowance given is 15%.
 Solution

(a) Normal time:

Tn = 0.56(1.00) + 0.25(0.80) + 0.50(1.0)+ 1.10(1.0)/5
= 1.53 min
(b) Standard time:
Tstd = 1.53(1 + 0.15) = 1.76 min
 Time Study Example 5
A direct time study was taken on a manual work
element using the continuous method. The
regular cycle consisted of three elements, a, b,
and c.
Work element a b c
Observed time (sec) 0.10 0.38 0.50
Performance rating 90% 100% 110%

Determine the standard time for the work with

allowance given is 10%.
 Solution
38 sec – 10 sec = 28 sec
50 sec – 38 sec = 12 sec
(a) Normal time:
Work element a b c .
Observed time (sec) 10 38 50
Time of each element 10 28 12
Performance rating 90% 100% 110%

Tn = 10(0.90) + 28(1.00) + 12(1.1) = 50.2 sec

(b) Standard time:
Tstd = 50.2 (1 + 0.10) = 55.22 sec
 Machine Cycle in the Task
 If the work cycle includes machine-paced
elements, then standard time may include a
machine allowance applied to the machine
time
Tstd = Tnw(1 + Apfd) + Tm(1 + Am)
where Tnw = normal time for worker (external)
elements, Tm = machine cycle time (assumed
constant), and Am = machine allowance
 Cycle-to-Cycle Time Variations
Result from the following:
 Variations in hand and body motions
 Variation in the placement of parts and tools
 Variations in the quality of the starting work
units
 Operator mistakes
 Variations in worker pace
 Timing errors by analyst
 Number of Cycles to be Timed
After several cycles, calculate sample
standard deviation s
 x  x 
2
s=
n 1
Using the Student t distribution,
2
 t / 2 s 
n=  
 kx 

k = accuracy level (acceptable error) desired in percent of the job element, expressed as
a decimal
Number of Cycles to be Timed
 Number of Cycles to be Timed
(example)
Seven cycles have been observed during a direct time study.
The mean for the largest element time = 0.85 min, and the
corresponding sample standard deviation s = 0.15 min, which
was also the largest. If the analyst wants to be 95% confident
that the mean of the sample was within 10% of the true mean,
analyse the number of observations should be taken.
Solution:
For dof = 6 degrees of freedom and  = 0.05, t = 2.447
2
 t / 2 s   (2.447 )(0.15) 
2

n      18 .65
 k x   (0.10 )(0.85) 
rounded to 19 total observations
We need 19 – 7 = 12 more observations.
 Number of Cycles to be Timed
(example)
A total of 9 cycles have been observed during a time study. The
mean for the largest element time = 0.80 min, and the
corresponding sample standard deviation s = 0.15 min, which
was also the largest. If the analyst wants to be 95% confident
that the mean of the sample was within 0.10 min of the true
mean, analyse the number of observations should be taken.
Solution:
For dof= 8 degrees of freedom and  = 0.05, t = 2.306
Given that accuracy level, 0.10 min
2
 t / 2 s   (2.306 )(0.15) 
2

n      11 .96
 kx   (0.10 ) 
rounded to 12 total observations
We need 12 – 9 = 3 more observations.
 Performance Rating
Analyst observes and rates the worker’s
performance relative to the definition of
standard performance
 The most difficult and controversial step in
direct time study
 Potential conflict of interest between the
worker and the analyst
 Most common performance rating method is
based on speed or pace
 Traits of a Good Rating System
 Consistency among tasks
 A worker who can perform at 125% on one
task should be able to do the same on other
tasks
 Consistency among analysts
 Easy to explain and easy to understand
 Based on a well-defined concept of standard
performance
 Rate performance during the observation
 Worker notification
 Time Study Equipment

1. Stopwatch
 Mechanical stopwatches
 Electronic stopwatches
2. Video cameras
 Provides visual and audio record of
method used by worker
3. Computerized techniques in direct time study
 Use of PCs