Method Study: Definitions, Scope, Objectives, and Analytical Techniques

Learning Outcomes and Key Concepts

• Learning Outcomes:

  • Define "method study".
  • Discuss the nature and scope of method study.
  • Explain the objectives of method study.
  • Distinguish between key techniques of method study: brainstorming, preliminary surveys, flow process charts, outline process charts, two-handed process charts, and flow diagrams.
  • Name and describe standard process chart symbols.
  • Describe and illustrate process chart symbols using practical workplace examples.

• Key Concepts:

  • Method study
  • Brainstorming
  • Flow process charts
  • Outline process charts
  • Two-handed process charts
  • Flow diagram
  • Operation
  • Inspection
  • Transport
  • Delay (temporary storage)
  • Permanent storage
  • Process chart symbols

Definitions and Core Principles of Method Study

• Formal Definitions:

  • Kanawaty (1995:75): Method study is defined as "the systematic recording and critical examination of ways of doing things in order to make improvements".
  • Unisa (2007:174): Defined as the "systematic recording and critical examination of those factors and resources involved in an existing or proposed job/operation, in order to develop an easier and more efficient method and to reduce costs".
  • Munyai, Mbonyane and Mbohwa (2018:71-72): Considered a technique exercised systematically to establish the most economical method to simplify and improve workers' activities in the workplace.
  • Sookdeo (2020:174): Defined as "a technique of the concept work study and is primarily concerned with improving the methods of working".

• Technological Progression Example in Logistics Operations:

  • Work methods evolve across distinct efficiency levels:
  1. Manual Material Handling: Direct manual lifting of materials by workers.
  2. Mechanized Handling: Utilizing a trolley and a forklift to load and move packaged boxes.
  3. Advanced Technological System: Implementing robotics and conveyor belts to automatically offload similar-sized boxes for smart logistics operations.
  • Primary Purpose: Upgrading to automated and technological systems improves the supply chain process by saving time and reducing operational costs.

Nature and Scope of Method Study

• Nature of Method Study:

  • Systematic Problem-Solving: Relies on a structured, systematic methodology to solve workplace operational problems.
  • Efficiency and Effectiveness: Aims to refine work methods and processes by eliminating unnecessary and ineffective operations, movements, and steps.
  • Cognitive Requirements: Work study specialists must combine analytical thinking with creative thinking to devise viable alternative solutions.

• Scope of Method Study:

  • Organizational Reach: Applies universally across all organizational tiers, from entry-level subordinates to executive senior management.
  • Operational Focus: Concentrates on workplace methods, processes, and procedures to optimize organizational outcomes.
  • Technique Deployment: Implements diverse analytical techniques to ensure smooth and cost-effective operations.

Objectives of Method Study

• Core Objectives (Unisa 2005:162; Sookdeo 2014:60):

  • Layout & Design: Proper planning and design of the factory, plant, or designated workplace layout to ensure optimal workflow.
  • Standardized Execution: Implementation of properly executed standard work procedures, processes, and work methods.
  • Resource Optimization: Optimal utilization of factory space, plant infrastructure, raw materials, machinery, and equipment.
  • Favorable Working Environment: Establishing safe, safe, and clean working conditions, including:
  • Appropriate lighting and adequate ventilation.
  • Rigorous cleanliness and routine workplace maintenance.
  • Regular preventive maintenance of machinery.
  • Methodical storage of tools in designated, designated areas (good housekeeping).
  • Enhanced employee occupational safety.
  • Product Design Improvement: Enhancing design specifications and improving the overall design of completed products.

• Operational Strategy & Implementation Examples:

  • Workflow Planning: Management must engage all operational parties in planning workflow layouts to maximize productivity performance.
  • Just-In-Time (JIT) Work Cells: Organizing wheel assembly module preparation in specialized work cells for JIT delivery directly to a motorcycle assembly line (Heizer & Render 2016:319).
  • Housekeeping and Maintenance Impact: Addressing operational hazards such as leaking machinery or poor lighting directly prevents drops in productivity and protects employee wellbeing.

Method Study Techniques: Brainstorming and Preliminary Survey

• Brainstorming:

  • Definition & Mechanics (Munyai, Mbonyane & Mbohwa 2018:191-194): A collaborative technique bringing management and work study specialists together to evaluate technical guidelines.
  • Target Areas: Focuses on identifying input resource factor challenges that impede operational processes in the workplace.
  • Objective: Formulate targeted corrective measures through work study applications to drive organizational productivity gains.

• Preliminary Survey:

  • Definition (Unisa 2005:187-191): An initial exploratory investigation using diagnostic tools such as interviews, observations, and questionnaires to gather workplace operational data.
  • Functions and Specific Purposes:
  • Secure the direct cooperation of supervisors and operational subordinates.
  • Identify and define the central operational problem as concisely as possible.
  • Establish the precise timing and duration for the full investigation.
  • Conduct a pilot study to determine the direction of the investigation and assess whether a full-scale study is financially and operationally justified based on limited preliminary data.
  • Validate whether the problem was defined accurately originally, pinpoint root causes, and project potential operational impacts.
  • Define the boundary and scope of the problem to guarantee the final solution addresses the root cause comprehensively.
  • Determine whether the problem falls strictly within the domain of work study.
  • Gauge worker attitudes and morale affected by the upcoming study.
  • Verify the availability of financial funds required to fund the investigation and implement proposed changes.
  • Select the most cost-effective data collection methods (e.g., face-to-face interviews, structured questionnaires, direct physical observations, document reviews, or process charts).

Data Collection Tools in Preliminary Surveys

• Interviews (Munyai, Mbonyane & Mbohwa 2018:181-183):

  • Direct face-to-face dialogue between work study specialists and division managers.
  • Aimed at capturing deep context regarding operational backgrounds and divisional requirements.

• Questionnaires (Munyai, Mbonyane & Mbohwa 2018:265):

  • Structured documentation and field notes recorded during investigation to assist management in identifying and rectifying operational bottlenecks.
  • Likert Scale Measurement Framework (Cooper & Schindler 2016:276):
  • Uses a 5-point summated rating scale (interval data) with descending numerical codes:
    • Code $5$: Strongly agree
    • Code $4$: Agree
    • Code $3$: Neither agree nor disagree
    • Code $2$: Disagree
    • Code $1$: Strongly disagree
  • Core Activity Metrics Evaluated:
    1. Perform material quality check before operation.
    2. Ensure machine is maintained regularly.
    3. Manage waste elimination.
    4. Perform product quality check after operation.
    5. Generate products as per customers' requirements.

• Observations (Unisa 2005:206-207):

  • Direct physical examination of operational activities where work study specialists record real-time factual evidence (e.g., monitoring a forklift driver loading and moving palletized boxes to a warehouse).
  • Advantages:
  • Provides precise, direct recording of real worker actions.
  • Allows specialists to introduce themselves and establish trust/cooperation.
  • Permits recording of task activities even if workers are initially hesitant.
  • Disadvantages:
  • Performance Distortion: Workers may alter behavior to impress specialists, performing unrealistically above standard norms.
  • Nervousness: Workers may experience anxiety under observation, leading to performance below standard norms.
  • Time Intensity: Requires long, repetitive observation cycles across multiple work shifts.

Structure and Categories of Process Charts

• General Structure of Process Charts (Unisa 2005:235):

  • Heading: Contains metadata including department/division/section/unit name, investigation date, study number, clear task description, method status (present or proposed), start/end times, and analyst name.
  • Main Body: Chronological, sequential record of every activity step from start to finish using concise descriptions alongside corresponding symbols.
  • Summary: Analytical table tallying total occurrences of each symbol, total distance traveled, and total time duration.

• Standard Process Chart Symbols and Definitions:

  • Operation (Circle Symbol):
  • Definition: Indicates intentional modification or transformation of raw material or semi-finished items using human labor, machinery, or tools.
  • General Example: Loading a pallet with packaged boxes.
  • Worker Type Example: Chef prepares (cuts) food for cooking.
  • Material Type Example: Food is prepared for cooking.
  • Equipment Type Example: A knife is used to cut food for cooking.
  • Inspection (Square Symbol):
  • Definition: Indicates checking or testing quality standards, or counting for quantity verification.
  • General Example: Counting the number of boxes loaded onto a forklift.
  • Worker Type Example: Butcher examines the freshness of meat.
  • Material Type Example: Meat is checked in a fridge by a butcher to ensure freshness (quality control).
  • Transport (Arrow Symbol):
  • Definition: Indicates movement of workers, materials, or equipment between locations or workstations.
  • General Example: Forklift driver transports boxes to the warehouse.
  • Worker Type Example: Worker transports a loaded box using a pallet jack to a shelf.
  • Material Type Example: A loaded box is transported to a shelf using a pallet jack.
  • Equipment Type Example: A pallet jack is utilized to transport a loaded box to a shelf.
  • Temporary Storage or Delay ("D" Symbol):
  • Definition: Indicates an unplanned delay or temporary wait in the sequence of events.
  • General Example: Waiting for a warehouse supervisor who is counting other stock.
  • Worker Type Example: A worker waits for instructions from the supervisor to fill bottles with juice and package them.
  • Material Type Example: Bottles are waiting to be filled with juice and packaged.
  • Permanent Storage (Inverted Triangle Symbol):
  • Definition: Controlled storage where materials are held under formal authorization or retained for long-term reference.
  • General Example: Packaged boxes kept securely on warehouse shelves.
  • Worker Type Example: Shelf packer permanently stores drinks for customer consumption.
  • Material Type Example: Drinks are permanently stored for customer consumption.
  • Merged Activities (Combined Circle and Square Symbol):
  • Definition: Indicates simultaneous execution of operation and inspection by the same operator at a single workstation.
  • General Example: Warehouse supervisor checks packaging quality while packing boxes onto a shelf.
  • Worker Type Example: Chef inspects food while cooking.
  • Material Type Example: Food is inspected by the chef while being cooked.
  • Equipment Type Example: A pan is used to check the food while the food is being cooked.

Types of Process Charts

• Flow Process Chart (Kanawaty 1995:89; Unisa 2005:209-212):

  • Definition: A process chart setting out the complete sequence of flow of a product, person, or procedure by recording all event occurrences using standard process chart symbols.
  • Categorizations:
  • Worker type: Tracks physical activities performed by a human worker.
  • Material type: Tracks physical handling, processing, and movement experienced by material.
  • Equipment type: Tracks usage and movement of tools or machinery.
  • Summary Block Tracking: Compares Present Method vs. Proposed Method across Operations, Transports, Delays, Storages, and Inspections, calculating net savings in Time (minutes), Distance (meters), and Cost (Rand).

• Outline Process Chart (Kanawaty 1995:84; Unisa 2005:221):

  • Definition: A high-level chart giving an overall view of a process by recording in sequence only main Operations and Inspections.
  • Key Structural Difference: Completely excludes transport, delay, and storage symbols to maintain a macro perspective.
  • Tracked Tally: Contains a summary tracking total count and combined duration of Operations and Inspections.

• Two-Handed Process Chart (Kanawaty 1995; Unisa 2005:240):

  • Definition: A micro-motion process chart recording synchronized activities of a worker's left and right hands (or limbs) relative to each other.
  • Symbols Used: Operation, Transport, Storage, and Delay symbols applied independently to each hand.
  • Recording Technique: Frequently conducted via close-up video analysis (e.g., observing an operator assembling a disk and brake pad into a vehicle wheel using both hands).
  • Structure: Maps step-by-step actions of the Left Hand directly adjacent to step-by-step actions of the Right Hand, complete with step counts and duration totals.

• Flow Diagram (Heizer & Render 2016:456):

  • Definition: A spatial scale drawing used to trace and analyze physical floor-movement paths of people, equipment, or materials across a workplace environment.

Self-Assessment and Practical Applications

• Core Analytical Tasks:
  • Formulating personal operational definitions for method study, brainstorming, preliminary surveys, flow process charts, outline process charts, two-handed process charts, and flow diagrams.
  • Classifying workplace activities using standard process chart symbols.
  • Constructing complete summary tables tracking operational savings across time ($minutes$), distance ($meters$), and financial metrics ($Rand$).