What is Method study and How to do? Implementation of Method study.

Method study

Method study is the systematic recording and critical examination of ways of doing things in order to make improvements

• Eliminate unnecessary movement

Basic approach to method study consists of the following steps:

1. Select
2. Record
3. Examine
4. Develop
5. Evaluate
6. Define
7. Install
8. Maintain

Selecting the work to be studied

Factors should be kept in mind:

- Economic or cost-effective considerations.

• Key profit-generating or costly operations, or with largest scrap/waste rate

• Bottlenecks or lengthy operations

• Involve repetitive work using a great deal of labor & likely to run for a long time

• Movements of material over long distances

- Technical or technological considerations.

• Acquire more advanced technology, whether in equipment or in processes

• Computerize (paperwork or inventory)

• Introduce automation in the production operation

- Human considerations.

• Operations cause dissatisfaction of workers

• Induce fatigue or monotony

• Unsafe or clumsy to operate

Record the facts

Basis for subsequent analysis and examination

• Provide the basis of critical examination & development of the improved method

The most commonly used recording techniques

- Charts

• Indicating process sequence

• Outline process chart

• Flow process chart (worker type, material type & equipment type)

• Procedure flowchart

• Time scale

• Multiple activity chart

- Diagrams

• Indicating movement

• Flow diagram

• String diagram

• Travel chart

Examine critically

The questioning technique

The means by which the critical examination is conducted, each activity being subjected in turn to a systematic and progressive series of questions

The primary questions

The secondary questions

Determine whether possible alternatives of place, sequence, persons and/or means are practicable and preferable as a means of improvement upon the existing method

These questions, in the above sequence, must be asked systematically every time a method study is undertaken. 

• They are the basis of successful method study.

Develop the improved method

“To ask the right question is to be halfway towards finding the right answer”

• What should be done?

• Where should it be done?

• When should it be done?

• Who should do it?

• How should it be done?

Evaluating alternative methods

Study highlights a number of possible changes and therefore a number of potential new methods.

Some may require further actions to be carried out before they can be implemented.

• The introduction of new equipment
• The building of new jigs or fixtures
• Operator training

To find preferred solution, need appropriate information on the alternative methods, the likely results of the proposed changes and the costs of implementation.

• Quantitative benefit (cost-benefit analysis)

• Qualitative benefit (job satisfaction, employee morale or industrial relations)

Use "pseudo-quantitative" techniques to express the qualitative benefits in quantitative terms for an overall evaluation.

Defining the improved method

Prepare a written standard, also known as an "operative instruction sheet"

• The tools and equipment to be used and the general operating conditions
• Description of the method (very detailed)
• Workplace layout and sketches of special tools, jigs or fixtures.

- Improved method for future reference
- Explain the new method to management, supervisors, operatives & all
- Aid to training or retraining operatives
- Basis on which time studies may be taken for setting standards

Installing the improved method

Perhaps the most difficult of all

• Active support is required from management and trade unions alike
• Define personal qualities of the work study person
• Ability to explain clearly and simply what he or she is trying to do

Installation stages:

• Gaining acceptance of the change by management
• Gaining acceptance of the change by the departmental supervision
• Gaining acceptance of the change by the workers
• Preparing to make the changes
• Controlling the change-over

“Decide when the change-over should take place even though a new method is more efficient and will ultimately result in greater output”

Maintaining the new method

When a method is installed, it should be maintained

• Specified form
• Workers should not be permitted to slip back into old methods
• Introduce elements not allowed

“Human nature being what it is, workers and supervisors or charge hands will tend to allow a drift away from the method laid down, if there is no check”