Method Study

Method Study

I. Introduction

Method Study is a key concept in Industrial Engineering and Supply Chain that focuses on improving efficiency and productivity in processes. By analyzing and optimizing methods, Method Study helps organizations reduce waste, increase output, and improve overall performance.

A. Importance of Method Study in Industrial Engineering and Supply Chain

Method Study plays a crucial role in Industrial Engineering and Supply Chain for several reasons:

1. Cost Reduction: By identifying and eliminating unnecessary steps, Method Study helps reduce costs associated with labor, materials, and time.
2. Increased Productivity: By streamlining processes and improving workflow, Method Study enhances productivity and output.
3. Quality Improvement: Method Study helps identify bottlenecks and areas for improvement, leading to enhanced quality and customer satisfaction.
4. Safety Enhancement: Method Study helps identify potential hazards and risks, allowing organizations to implement safety measures and reduce accidents.

B. Fundamentals of Method Study

Method Study is based on the following fundamental principles:

1. Systematic Approach: Method Study follows a systematic approach to analyze and improve methods, ensuring comprehensive and effective results.
2. Data Collection: Method Study relies on accurate data collection to identify inefficiencies and areas for improvement.
3. Collaboration: Method Study involves collaboration between different stakeholders, including workers, supervisors, and management, to ensure successful implementation of new methods.

II. Key Concepts and Principles

A. Definition of Method Study

Method Study can be defined as the systematic examination and analysis of existing methods, followed by the development and implementation of improved methods.

B. Symbols in Method Study

Symbols play a crucial role in Method Study as they represent different elements and actions in a process. Some commonly used symbols in Method Study include:

• Operation: Represents a specific action or task
• Transportation: Represents the movement of materials or products
• Inspection: Represents the quality control process
• Delay: Represents waiting time or idle time

C. Flow Process Chart

A Flow Process Chart is a visual representation of a process that shows the sequence of activities, the flow of materials or information, and the decision points. It helps identify inefficiencies, bottlenecks, and areas for improvement.

D. Flow Diagram

A Flow Diagram is a more detailed version of a Flow Process Chart that includes additional information such as distances, quantities, and timings. It provides a comprehensive view of the process and helps in analyzing and improving the method.

E. Machine Chart

A Machine Chart is used to analyze and optimize machine operations. It helps identify the sequence of operations, machine utilization, and potential areas for improvement.

F. Two Hand Chart

A Two Hand Chart is used to analyze tasks that require the use of both hands simultaneously. It helps identify potential ergonomic issues and suggests improvements to reduce fatigue and improve efficiency.

G. Critical Examination

Critical Examination involves a detailed analysis of the existing method to identify inefficiencies, waste, and areas for improvement. It includes questioning every aspect of the method and challenging established practices.

H. Developing a New Method

Based on the findings from the critical examination, a new method is developed using the principles of motion economy. The new method aims to eliminate waste, reduce unnecessary movements, and improve overall efficiency.

I. Principles of Motion Economy

The Principles of Motion Economy are a set of guidelines that help in the development of efficient methods. Some key principles include:

• Simplicity: Methods should be simple and easy to understand.
• Minimization of Movement: Unnecessary movements should be eliminated to reduce fatigue and improve efficiency.
• Standardization: Standardized methods and tools should be used to ensure consistency and reduce errors.
• Ergonomics: Methods should be designed to minimize physical strain and promote worker safety and comfort.

J. Therblig Symbols

Therblig Symbols are a set of symbols used to represent different types of human movements in Method Study. Some commonly used Therblig Symbols include:

• Search: Represents the action of searching for a tool or material
• Grasp: Represents the action of picking up or holding an object
• Transport Empty: Represents the movement of an empty container or material
• Transport Loaded: Represents the movement of a loaded container or material

K. SIMO Chart

A SIMO (Sequential, Interdependent, Multiple Operator) Chart is used to analyze and optimize tasks that involve multiple operators working in sequence. It helps identify potential bottlenecks, coordination issues, and areas for improvement.

III. Step-by-step Walkthrough of Typical Problems and Solutions

Method Study follows a systematic approach to analyze and improve methods. The following steps provide a general framework for conducting Method Study:

A. Identify the need for Method Study

The first step in Method Study is to identify the need for improvement. This can be done by analyzing performance metrics, receiving feedback from workers, or identifying specific problem areas.

B. Collect data and analyze the existing method

Once the need for improvement is identified, data is collected to analyze the existing method. This includes observing the process, measuring cycle times, and gathering information about inputs and outputs.

C. Create a flow process chart or flow diagram

Based on the data collected, a flow process chart or flow diagram is created to visualize the sequence of activities, flow of materials, and decision points. This helps identify inefficiencies and areas for improvement.

D. Use symbols and charts to identify inefficiencies and areas for improvement

Symbols and charts, such as the ones mentioned earlier, are used to identify inefficiencies, bottlenecks, and areas for improvement in the method. This includes analyzing the sequence of operations, transportation distances, waiting times, and ergonomic issues.

E. Conduct a critical examination of the method

A critical examination is conducted to question every aspect of the method and challenge established practices. This helps identify waste, unnecessary movements, and potential improvements.

F. Develop a new method using the principles of motion economy

Based on the findings from the critical examination, a new method is developed using the principles of motion economy. This involves simplifying the method, minimizing unnecessary movements, standardizing processes, and considering ergonomic factors.

G. Implement and evaluate the new method

The new method is implemented and evaluated to assess its effectiveness. This includes monitoring performance metrics, gathering feedback from workers, and making adjustments as necessary.

IV. Real-world Applications and Examples

Method Study has wide-ranging applications in various industries. Some examples include:

A. Application of Method Study in manufacturing processes

Method Study is commonly used in manufacturing processes to improve efficiency, reduce waste, and enhance productivity. For example, Method Study can be applied to assembly lines to identify bottlenecks, optimize workstations, and improve overall workflow.

B. Application of Method Study in service industries

Method Study is also applicable in service industries, such as healthcare, logistics, and hospitality. For instance, Method Study can be used in hospitals to streamline patient flow, optimize resource allocation, and reduce waiting times.

C. Examples of successful implementation of Method Study

There are numerous examples of successful implementation of Method Study. One notable example is the Toyota Production System, which incorporates Method Study principles to achieve high levels of efficiency, quality, and customer satisfaction.

V. Advantages and Disadvantages of Method Study

A. Advantages of Method Study

• Cost Reduction: Method Study helps reduce costs associated with labor, materials, and time.
• Increased Productivity: Method Study enhances productivity and output by streamlining processes and improving workflow.
• Quality Improvement: Method Study helps identify bottlenecks and areas for improvement, leading to enhanced quality and customer satisfaction.
• Safety Enhancement: Method Study helps identify potential hazards and risks, allowing organizations to implement safety measures and reduce accidents.

B. Disadvantages of Method Study

• Time-consuming: Method Study requires time and effort to collect data, analyze methods, and implement changes.
• Resistance to Change: Some employees may resist changes to established methods, leading to challenges in implementation.
• Lack of Expertise: Method Study requires expertise in data collection, analysis, and process optimization, which may not be readily available in all organizations.

VI. Conclusion

Method Study is a valuable tool in Industrial Engineering and Supply Chain that helps organizations improve efficiency, reduce waste, and enhance productivity. By following a systematic approach and utilizing key concepts and principles, Method Study enables organizations to optimize methods, achieve cost savings, and deliver high-quality products and services.

In conclusion, Method Study is an essential aspect of Industrial Engineering and Supply Chain that offers numerous benefits and applications. By understanding the key concepts, principles, and steps involved in Method Study, professionals in this field can make informed decisions and drive continuous improvement in their organizations.

Summary

Method Study is a key concept in Industrial Engineering and Supply Chain that focuses on improving efficiency and productivity in processes. It involves the systematic examination and analysis of existing methods, followed by the development and implementation of improved methods. Method Study utilizes symbols, flow process charts, flow diagrams, machine charts, two hand charts, critical examination, and the principles of motion economy to identify inefficiencies, eliminate waste, and improve overall efficiency. It follows a step-by-step approach that includes identifying the need for Method Study, collecting and analyzing data, creating visual representations, conducting a critical examination, developing a new method, and implementing and evaluating the new method. Method Study has real-world applications in manufacturing processes and service industries, and it offers advantages such as cost reduction, increased productivity, quality improvement, and safety enhancement. However, it also has disadvantages such as being time-consuming, facing resistance to change, and requiring expertise. Overall, Method Study is a valuable tool that helps organizations optimize methods, achieve cost savings, and deliver high-quality products and services.

Analogy

Method Study can be compared to renovating a house. Just like Method Study aims to improve efficiency and productivity in processes, renovating a house aims to improve its functionality and aesthetics. In both cases, a systematic approach is followed, data is collected and analyzed, and improvements are made based on identified inefficiencies. Symbols and charts, similar to architectural plans, are used to visualize the existing layout and identify areas for improvement. The principles of motion economy can be compared to the principles of interior design, where simplicity, minimization of movement, standardization, and ergonomics are considered. The implementation and evaluation of the new method can be compared to the actual renovation process, where changes are made, and the final result is assessed for its effectiveness. Just as Method Study offers advantages such as cost reduction and increased productivity, renovating a house offers benefits such as improved functionality and increased property value.