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July 10, 2025

Time Study Weaknesses

 

Time studies are a common technique used in industrial engineering and business management to measure the time required to complete a task and establish standard times. While they can be valuable for improving efficiency and productivity, they also come with several significant weaknesses:



 


 

1. Human Factors and Subjectivity:

  • Hawthorne Effect: Workers often perform differently (either faster or slower) when they know they are being observed. This can lead to inaccurate time measurements that don't reflect typical performance.

  • Observer Bias: The time study observer's skill, judgment, and even unconscious biases can influence the data collected. They might unconsciously rate performance higher or lower, or miss subtle variations.

  • Worker Resistance/Demotivation: Employees may feel micromanaged, distrusted, or resentful if they perceive time studies as a surveillance tool. This can decrease morale, engagement, and even lead to deliberate "gaming" of the system (e.g., slowing down).

  • Difficulty in Capturing Non-Tangible Work: Creative thinking, problem-solving, collaboration, and strategic decision-making are difficult to quantify with a stopwatch. Time studies tend to focus on repetitive, measurable tasks, overlooking these crucial but less visible aspects of work.

  • Fatigue and Variation: Human performance naturally varies due to fatigue, personal factors (PFD allowances), and external disruptions. A simple time study might not adequately account for these variations, leading to unrealistic standards.

2. Methodological Limitations:

  • Not Suitable for Non-Repetitive or Non-Standardized Jobs: Time studies are most effective for tasks that are highly repetitive and have clearly defined, standardized procedures. They are less useful for jobs that involve significant variability, creativity, or indirect labor.

  • Inaccurate Representation of Productivity: Simply measuring the time taken for a task doesn't always reflect true productivity. Quality, innovation, and customer satisfaction can be overlooked in favor of speed.

  • Insufficient Sample Size: If the time study is based on too few observations or an unrepresentative sample of workers, the resulting standards may be inaccurate and unreliable.

  • Static Nature: Time studies capture a snapshot of a process at a specific time. They may not account for changes in technology, work processes, or external factors that can quickly render the established standards obsolete.

  • Focus on Measurable Tasks Only: This can lead to a narrow view of efficiency, neglecting the broader process and factors like communication and collaboration that impact overall effectiveness.

3. Organizational and Cultural Impacts:

  • Shift to Quantity Over Quality: If incentives are tied directly to time-based output standards, employees might prioritize speed over the quality of their work.

  • Increased Stress and Burnout: Unrealistic time standards can lead to excessive pressure, longer workdays, and increased stress and burnout among employees.

  • Discouraging Team Collaboration: When individuals are measured on their own time, it can discourage them from assisting colleagues or engaging in collaborative tasks that might impact their individual metrics.

  • Negative Impact on Company Culture: A culture of constant monitoring and micromanagement fostered by poorly implemented time studies can erode trust, foster a competitive atmosphere, and undermine employee autonomy.

  • Hindrance to Flexible Work Arrangements: Strict time tracking can be incompatible with flexible work arrangements, which are increasingly valued in modern workplaces.

4. Resource Intensive:

  • Time and Cost: Conducting a thorough time study requires significant time, skilled personnel (trained observers), and sometimes specialized equipment. This can be a deterrent for smaller businesses or those with limited resources.

In summary, while time studies can provide valuable data for process improvement, their effectiveness is heavily dependent on careful planning, skilled execution, and a clear understanding of their potential limitations and human impacts. To mitigate these weaknesses, it's crucial to combine time studies with other process improvement techniques, involve employees in the analysis, and focus on a holistic view of productivity that encompasses quality, collaboration, and employee well-being.

 

July 1, 2025

Work content measurement in the garments industry.

 

✅ What Is Work Content Measurement?

Work content measurement refers to the process of determining the amount of time and effort required to complete a specific task or operation in garment production. It involves analyzing tasks such as cutting, stitching, pressing, finishing, etc., to establish standard times and efficiency benchmarks.

 

   


🛠️ How Is Work Content Measured?

Common techniques include:

  • Time Study: Using stopwatch or digital tools to measure task durations.

  • Predetermined Motion Time Systems (PMTS): Such as GSD or MODAPTS, which assign standard times to small motions.

  • Work Sampling: Observing operations at intervals to estimate task distribution.

  • Standard Minute Value (SMV): Calculated time for completing a task under standard conditions.

 

March 15, 2023

Problem Solving: Plan-Do-Check-Act

Description:

This tool provides guidelines for using the Plan-Do-Check-Act approach and the steps to engage in the process.

How it can be used:

Effective problem-solving requires planning, testing, reviewing and refining a solution. The Plan-Do Check-Act (PDCA) cycle is a tool that provides a structured process to approach problem solving. Follow the steps below when you need a problem-solving approach that requires a methodical yet iterative process. Just as a circle has no end, the PDCA cycle should be repeated again and again for continuous improvement.

Benefits of using PDCA:

• To identify new solutions and improvements to processes that are frequently repeated

• To explore potential solutions to problems and make improvements using a controlled approach before selecting one for full implementation

• To avoid wasting resources due to full implementation of an ineffective solution When to use PDCA:

• As a model for continuous improvement

• When developing a new or improved design of a process, product or service

• When defining a repetitive work process

• When planning data collection to verify and prioritize issues The four phases in the Plan Do-Check-Act Cycle are:


1. Plan:

• Identify the problem

• Analyze the problem

• Map the process that is at the root of the problem

• Gather information required to identify a solution


2. Do:

• Generate several possible solutions

• Select the best potential solution

• Test a potential solution using a small-scale approach such as a pilot project or test trial

*Note that the ‘Do’ phase refers to ‘Try’ or ‘Test’. Implementation happens in the ‘Act’ phase.


3. Check:

• Measure the effectiveness of the pilot project or trial

• Identify what was learned

• Analyze whether and how it could be improved

• Depending on how successful the pilot project or trial was, the number of areas for improvement, and the scope of the initiative, consider repeating the ‘Do’ and ‘Check’ phases incorporating the additional improvements

• Once you confirm that the costs of repeating the ‘Do-Check’ sub-cycle further would outweigh any additional benefits, move onto the ‘Act’ phase


4. Act:

• Implement the improved solution

• Continue measuring to ensure the solution is working

• Loop back to the ‘Plan’ phase and seek further areas for improvement


Some examples of the types of activities during each phase are:



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Time Study Weaknesses

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