🔄 YESTERDAY RE-KNOCK: Standardization & Simplification
Yesterday, we explored the techniques that ensure uniform quality and cost-effectiveness. We learned that Standardisation is about setting benchmarks for every business activity, while Simplification aims at eliminating unnecessary variety and sizes to save inventory costs. Today, we move into the actual physical performance of work. We dive into Method Study and Motion Study—two techniques used to find the most efficient way to perform a task while cutting out wasteful movements.
Technique 4: Method Study
The objective of method study is to find out one best way of doing the job. There are various methods of doing a job. To determine the best way, several parameters should be considered, right from the procurement of raw materials till the final product is delivered to the customer.
Taylor believed that every production activity—from assembly to delivery—should be scientifically analyzed. The aim is to minimize the cost of production and maximize the quality and satisfaction of the customer. In my experience, finding the "one best way" often involves comparing different sequences of work. For example, in a car manufacturing plant, should the engine be fitted before the doors or after? Method study provides the scientific data to answer this.
Key Benefits:- Cost Reduction: By streamlining the process and removing redundant steps.
- Maximum Efficiency: Machines and labor are used at their full potential.
- Uniformity: The process is standardized, leading to predictable results.
Technique 5: Motion Study
Motion study refers to the study of movements like lifting, putting objects, sitting, and changing positions, etc., which are undertaken while doing a typical job. The objective is to eliminate unnecessary and wasteful motions so that it takes less time to complete the job efficiently.
Taylor used stopwatches and various symbols/colors to identify three types of motions:
- Productive Motions: Actions that actually add value (e.g., a worker tightening a screw).
- Incidental Motions: Necessary but don't add direct value (e.g., reaching for the screwdriver).
- Unproductive Motions: Pure waste (e.g., a worker walking across the factory floor to find a screwdriver).
In my experience, the goal is to convert incidental motions into productive ones and completely kill the unproductive ones. In a large industrial setup in Bokaro, if a worker has to bend 500 times a day to pick up a part from the floor, they will get tired quickly. By placing the parts on a waist-high table, you eliminate the bending motion, saving both time and energy.
In a heavy engineering unit in Bokaro, a worker was found moving 20 meters every time he needed a specific tool. Through Motion Study, the tools were organized in a belt around his waist. This simple change eliminated "Unproductive Motion," reduced his fatigue, and increased the daily output by 15%. This is the practical application of Scientific Management.
NCERT Comparative Summary
| Technique | Primary Objective | Mantra |
|---|---|---|
| Method Study | Find the whole process flow. | "Find the One Best Way." |
| Motion Study | Analyze individual movements. | "Cut the Wasteful Moves." |
📝 Day 25: Work Study Check
1. The technique of finding out "One Best Way" of doing the job is called:
a) Motion Study
b) Time Study
c) Method Study
d) Fatigue Study
Click to view Answer
Correct Answer: (c) Method Study.
Logic: Method study looks at the entire sequence of operations to find the most efficient process.
2. Motion Study helps in identifying and eliminating:
a) Standard raw materials
b) Unproductive movements
c) Scientific selection
d) Functional specialists
Click to view Answer
Correct Answer: (b) Unproductive movements.
Logic: By cutting out waste motions, Taylor ensured that workers remained productive without extra strain.
3. THE CASE STUDY:
(a) Techniques:
"Agrawal Sweets" in Patna noticed that during the festive season, the time taken to pack a box of sweets was too long. After observing the workers, the manager realized that the workers had to stand up and walk to a different table to get the decorative ribbons. Moreover, the packing was being done in 7 steps which could logically be done in 4.
(a) Identify the two Taylor's techniques the manager should use here.
(b) How will these techniques help in improving efficiency?
Click to view Master Solution
1. **Method Study:** To reduce the packing process from 7 steps to the "one best" 4-step method.
2. **Motion Study:** To eliminate the unproductive movement of walking to the other table for ribbons.
(b) Impact: Method study will streamline the process, while motion study will save physical energy and time, leading to much higher output per hour during the rush season.
Further Reading
- STUDY NOTE: Unit 2: Principles of Management - Full Detailed Notes
- REVISION: Unit 2: Principles of Management - Quick Revision
- CASE STUDY: Unit 2: Principles of Management - Solved Case Studies
Teaser for Tomorrow: We have fixed the "Way" and the "Move." Now, let’s fix the "Time" and the "Rest." Tomorrow, we explore Time Study and the science of physical exhaustion—Fatigue Study. We'll see how managers in Siliguri and Ranchi decide exactly how many tea breaks a worker needs!
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