🔄 YESTERDAY RE-KNOCK: The Path and the Motion
Yesterday, we analyzed the physical flow of industrial work through Method Study and Motion Study. We discovered Taylor's obsession with finding the "one best way" to perform a task and the importance of cutting out unproductive movements to save energy. We saw how a simple change in tool placement can spark a productivity revolution on a shop floor in Bokaro. Today, we focus on the two remaining pillars of Work Study: Time Study and Fatigue Study. We’ll learn how to measure the "cost of a minute" and the "necessity of a break."
Technique 6: Time Study
Time study determines the standard time taken to perform a well-defined job. Taylor advocated that every task should be timed using a stopwatch. This is not about timing one worker once; it involves timing several workers over many cycles to arrive at an average "Standard Time."
In my experience, Time Study is the most practical tool for a manager. Without it, you are just guessing. If you are running a printing press in Patna, you need to know exactly how long it takes to bind 100 books. If you don't have a standard time, you can never tell if your workers are being efficient or just "slow-walking" the job.
Objectives of Time Study:- Determining the number of workers: Once you know how long one unit takes, you can calculate how many people you need to finish 10,000 units by a deadline.
- Framing Incentive Schemes: It helps distinguish between efficient and inefficient workers, allowing for fair bonus systems.
- Determining Labour Costs: It helps in accurate budgeting and pricing of products.
The Stop-Watch Logic
If the average time to produce one component in a Ranchi workshop is 20 minutes, the "Standard Time" is 20 minutes.
In an 8-hour shift (480 minutes), a worker should produce $480 / 20 = 24$ units.
Anyone producing 24 or more is efficient; anyone below is inefficient. This removes personal bias from performance appraisals.
Technique 7: Fatigue Study
A person is bound to feel tired physically and mentally if they work for a long period without a break. The objective of Fatigue Study is to determine the amount and frequency of rest intervals in completing a task.
Taylor recognized that "fatigue" is a scientific reality. If a worker is tired, their speed drops, their quality falls, and the risk of accidents in places like Adityapur’s industrial units increases significantly. Rest intervals allow the worker to regain their lost stamina.
Factors causing Fatigue:- Long working hours without a break.
- Doing unsuitable or heavy physical work.
- Uncordial relations with the boss.
- Poor working conditions (heat, noise, bad light).
In my experience, the frequency of breaks is often more important than the length. In a tea garden in Siliguri, a 10-minute break every 2 hours might be much more effective than one 40-minute break in the middle of the day. A scientific fatigue study involves observing at what point a worker's productivity starts to dip and providing a break just before that happens.
In a warehouse in Ranchi, workers loading heavy cement bags were found to be exhausted by 2:00 PM. Through Fatigue Study, the manager introduced two 15-minute "Stamina Breaks" at 11:00 AM and 3:30 PM. Surprisingly, even though the workers worked for 30 minutes less, the total number of bags loaded per day increased by 10%. Why? Because they worked at full speed during their active hours rather than dragging their feet while tired.
Summary Table: Time vs. Fatigue Study
| Feature | Time Study | Fatigue Study |
|---|---|---|
| Primary Tool | Stopwatch and Observation. | Productivity charts and stamina levels. |
| Main Goal | To set a standard time for a task. | To set rest intervals (frequency & duration). |
| Key Outcome | Helps calculate labor cost & number of workers. | Reduces accidents and maintains peak speed. |
📝 Day 26: Work Study Evaluation
1. "To determine the number of workers to be employed" is an objective of:
a) Motion Study
b) Fatigue Study
c) Time Study
d) Method Study
Click to view Answer
Correct Answer: (c) Time Study.
Logic: Once you know the time taken per unit, you can mathematically derive the total manpower required for any volume of work.
2. Fatigue Study is conducted to find out:
a) The one best way of doing a job.
b) The unproductive motions of a worker.
c) The amount and frequency of rest intervals.
d) The standard time for a task.
Click to view Answer
Correct Answer: (c).
Logic: Fatigue study is purely about managing human stamina through rest.
3. THE CASE STUDY:
1. Fatigue Study: To solve the evening productivity drop. By analyzing when the fatigue sets in, Mr. Das can introduce scheduled rest intervals to help workers recover their energy and maintain a steady sorting speed throughout the day.
"Mr. Das" is the manager of a large courier sorting center in Siliguri. He noticed that his workers were very fast in the morning but by evening, the number of parcels sorted per hour fell by 40%. He also realized he had no idea how many workers he should hire for the upcoming 'Big Sale' next month.
Which two techniques of Taylor should Mr. Das apply to solve these specific problems? Explain how they will help.
Click to view Master Solution
2. Time Study: To solve the hiring problem. By using a stopwatch to determine the "Standard Time" to sort one parcel, he can calculate the total hours needed for the projected 'Big Sale' volume and hire the exact number of workers required.
Further Reading
- STUDY NOTE: Unit 1: Nature and Significance - Comprehensive Study Note
- REVISION: Unit 4: Planning - Quick Revision Guide
- MCQs: Unit 3: Business Environment - Chapter-wise MCQs
Teaser for Tomorrow: We have measured the work. Now, let’s talk about the "Paycheck." Tomorrow, we explore Taylor's most powerful motivational tool: Differential Piece Wage System. We'll see how managers in Patna and Ranchi use money to separate the "pro-workers" from the "slow-movers"!
No comments:
Post a Comment