Work Measurement and Methods Improvement

LAWRENCE S. AFT is Professor of Industrial Engineering Technology at Southern Polytechnic State University in Marietta, Georgia, and President of Aft Systems, Inc., a management consulting firm. His numerous books include Quality Improvement Using Statistical Process Control and Fundamentals of Industrial Quality Control, Third Edition.

• I Productivity – An Introduction 11 Introduction 3Anecdotes 4Analysis 8Why is Productivity a Problem in the United States 10Ways to Improve Productivity 12A Role for Industrial Engineering 15What about Japan 17Where to From Here? 202 Methods Analysis 22Objectives 22Introduction 22The Scientific Method 24Summary 30II work Analysis 313 Graphical Productivity Analysis 33Objective 33Introduction 33Graphical Analysis Tools 34Summary 85Review Questions 86Practice Exercises 864 Work Methods Improvement 105Objectives 105Introduction 105Methods Improvement Defined 106The Best Method 107Therblig Analysis 109Principles of Motion Economy 117Man vs. Machine 125Selling the Solution 132Summary 138Review Questions 141Practice Exercise 141III Measuring Productivity 1455 Time Study 147Objectives 147Introduction 147Purpose of Work Measurement Studies 148Rating Job Performance 150PFD Allowances 151Calculating the Standard Time 152Conducting a Time Study 153Elemental Analysis 160Determining Number of Cycles to Time 169Potential Data Recording Difficulties 180Data Analysis 183Interpretation of Results 185Special Cases 189Summary 203Review Questions 203Practice Exercises 2046 Standard Data Systems 209Objectives 209Introduction 209The Purpose of Standard Data Systems 210Constructing Standard Data Systems 211Methodology for Developing Standard Data Systems 226Advantages of Standard Data Systems 241Limitations of Standard Data Systems 241Summary 244Appendix – Correlation and Regression Analysis 244Review Questions 249Practice Exercises 2507 Predetermined Time Systems 253Objectives 253Introductions 253The Purpose of Predetermined Time Standards 254Use of Predetermined Time Systems 255Application of a Hypothetical Predetermined Time System – AFTWAYS 256Advantages of Predetermined Time Systems 278Selecting a Predetermined Time System 278Limitations of Predetermined Time Systems 279Examples of Existing Predetermined Time Systems 279Summary 298Review Questions 298Practice Exercise 2988 Work Sampling 299Objectives 299Introduction 299Definition of Work Sampling 300Conducting a Study 305Advantages of Work Sampling 319Limitations of Work Sampling 320Summary 322Sample Size Determination 323Review Questions 324Practice Exercises 3249 Physiological Work Measurement 330Objectives 330Introduction 330Measuring Physiological Work 331Uses of Physiological Work Measurements 335Implications for Productivity 337Summary 338Review Questions 33910 Labor Reporting 340Introduction 340Constructing a Labor Variance Report 341Variation 343Labor Efficiency 348Using Labor Reporting and Work Sampling to Manage Staffing Levels 351Conclusion 359Practice Exercises 360IV Improving Productivity 36311 Introduction to Ergonomics 365Objectives 365Introduction 365Approach to Human Factors Design 366Work Design Considerations 373Industrial Applications of Ergonomics 380Summary 382Partial Listing of Design Guidebooks 383Review Questions 38412 Incentives to Increase Productivity 385Objectives 385Introduction 385Incentive System Design 388Types of Incentive Plans 390The Scanlon Plan 402The Lincoln electric Plan 404Summary 408Review Questions 408Practice Exercises 40913 Alternative Methods for Increasing Productivity 412Objectives 412Introduction 412Quality of Work Life 413Quality Control Circles 419Work Measurement and Continuous Improvement 429Alternative Work Pattern – Flextime 433Other Motivational Approaches to Productivity Improvement 434Summary 437Review Questions 438Bibliography 439Index 449