Procedure for Method Study: 6 Steps. Production Management

This article throws light upon the six steps involved in method study.
The steps are: 
1. Select 
2. Record 
3. Critical Examination 
4. Develop 
5. Install 

6. Maintain.

Step # 1. Select:

Select the work worth studying and define the objectives to be achieved. An objective may be to reduce the manufacturing cost, or to reduce bottlenecks or to reduce fatigue incurred by the workers in order to increase their efficiency.

Step # 2. Record:

Record all the relevant information pertaining to the existing method (if any) in details and in the form of a chart to obtain a more clear picture about the same.

Recording can be done with the help of following aids:

(a) Process Charts:

(i) Outline Process Chart:

An Outline Process Chart surveys and records an overall picture of the process and states only main events sequence-wise. It considers only (main) operations and inspections. Actually an outline process chart is the beginning of a detailed analysis.

 

Step # 3. Critical Examination:

Examine the recorded events critically and in sequence. Critical examination involves answering a number of questions. An activity can be eliminated, simplified or combined with another.

The basic questions are:

Purpose. – What is done?

Person. – Who does it?

Place. – Where is it done?

Means. – How is it done?

Sequence. – When is it done?

The above-mentioned five basic questions, individually are further subjected to enquiries like.

Why:

Why is it necessary, why he does it, why it is done there, why is it done by that method and why is it done at that time?

Alternative Ways of Doing:

What else could be done, who else could do it, where else it could be done, how else it could be done and when else it could be done.

Best Method of Doing:

What should be done, who should do it, where it should be done, how it should be done, and when it should be done.

Step # 4. Develop:

Develop the best method as resulted from critical examination and record it.

The developed method should be:

(i) Practical and feasible,

(ii) Safe and effective,

(iii) Economical, and

(iv) Acceptable to design, production control, quality control and sales departments.

Step # 5. Install:

Install the (best) developed method or the improved method. Installation involves three phases, namely-planning, arranging and implementing. During the first two stages the programme of installation (phase-wise) and a time table, are planned and the necessary arrangements of resources, equipment, tools and instructions to workers, over-time, etc., are made.

The implementation or actual installation involves the introduction of developed method as standard practice. Problems associated with the developed method should be carefully studied and remedied, if necessary. Installation phase is complete as soon as the new method starts working smoothly and satisfactorily and gives encouraging results (like saving in time, scrap reduction, etc.)

Step # 6. Maintain:

Maintain the new method, i.e., ensure the proper functioning of the installed method by periodic checks and verifications. The purpose of checks and reviews is to find if the method being practised is the same or it has deviated from the authorised one.

Reasons for deviation if any should be explored and the necessary changes may be made in the procedure being practised so that it reverts to the authorised one. Views of the workers, supervisors and other persons related with the authorised method can be of much help in exploring further improvements.