Time and Motion study
Introduction
What is Time and motion study?
Time and motion study is the systematic observation, analysis and measurement of the separate
steps in the performance of a specific job for the purpose of establishing a standard time for each
performance, improving procedures and increasing productivity. It is the systematic study of
human motions used to perform an operation. The purpose is to eliminate unnecessary motions
and to identify the best sequence of motion for maximum efficiency.
Time & Motion Study (LEGO Simulation Exercise)
1. Select time and motion study team
2. Ensure availability of LEGO, clip-board, stop watch, paper sheets, and camera
3. Select production location
4. Design product to assemble (30 assemblies)
5. Practice assembly process
6. Select operator, analyst, camera person, supervisor (not group leader)
7. Observe assembly process
8. Break the job into elements
9. Record all relevant information
10. Practice data collection to find potential problems
11. Collect time data, determine rating and allowances, observe motions
12. Calculate standard time (consider setups)
13. Brainstorm motion and workstation improvements
14. Implement improvements
15. Repeat time study
16. Calculate improvements (productivity, efficiency, quality, etc)
Purpose and objectives
Following are the objectives and purposes of time and motion study
To improve the methods or procedures adopted in performance of various jobs
To simplify the job and develop more economical methods
To determine how long it should take to carry out a given task
To reduce human effort by proper design of processes
To improve utilization of resources
Improving the layout of the facility
To develop suitable working conditions
Application of techniques designed to establish the time for a qualified worker to carry
out a specified task / job at a defined level of performance
Provides management with a means of measuring the time taken in the performance of a
process or operation
Work measurement sets standard time for carrying out the work
Reveals shortcomings of design, material and methods
Separates the effective time from the ineffective time
Shows the behavior and attitudes of workers
Helps estimate cost of processes / operations
Helps with line balancing problems
Helps with planning and scheduling of production and workers
Helps with estimates for tenders, cost, selling price, and delivery times
Helps to develop incentive programs and piece-work rate system
The limitations of time and motion study
Observers are not always competent
Those conducting the study are not always proficient in the job being observed
The actions observed are not always reflective of the group as a whole
Timing by direct observation may lead to inconsistency
Rating is a much disputed area in Time and Motion Study
It included individual expertise and judgment in various factors
The workers may resent the study if it is being used to determine the pay scale
Workers may change the rate at which they work
Pressure may increase mistakes made
Workers may alter normal work methods to disrupt the study
Specific Benefits of Time and Motion Studies
Internal
Works to verify that critical customer requirements and “Voice of” analysis are simultaneously
reviewed and taken into account
Sustains a level of consistency between the business and process/product improvement
Links Quality Management Systems directly to financial business performance
External
Gives credibility to Quality Management Systems by continuously improving products and
processes
Signifies an organization’s ability to deliver and sustain the benefits
Allowances
The normal time for an operation does not contain any allowances for the worker. It is
impossible to work throughout the day even though the most practicable, effective method has
been developed. Even under the best working method situation, the job will still demand the
expenditure of human effort and some allowance must therefore be made for recovery from
fatigue and for relaxation. Allowances must also be made to enable the worker to attend to his
personal needs. The allowances are categorized as:
(1) Relaxation allowance
(2) Interference allowance
(3)Contingency/Time allowance
Contingency/Time allowance:-
A contingency allowance is a small allowance of time which may be included in a standard time
to meet legitimate and expected items of work or delays. The precise measurement of which is
uneconomical because of their infrequent or irregular occurrence. This allowance provides for
small unavoidable delays as well as for occasional minor extra work:
Observed Time + Rating = Basic Time + Allowances = Standard Time
Some of the examples calling for contingency allowance are:
Tool breakage involving removal of tool from the holder and all other activities to insert
new tool into the tool holder
Power failures of small duration.
Obtaining the necessary tools and gauges from central tool store. Contingency allowance
should not exceed 5%.
References:-
1. Operations Management, by Roberta S. Russell & Bernard W. Taylor, 4th edition, Pearson
2. Principles of Operations Management, by J. Heizer & B. Render, 4th edition, Prentice-Hall
3. Productivity Engineering and Management, by David J. Sumanth, 1984, McGraw-Hill
4. Motion and Time Study, by Benjamin W. Niebel, 8th edition, 1988, Richard D. Irwin, Inc.
5. Operations Management, by Wlliam J. Steven, 11th edition published by McGraw Hill.
