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International Journal of
Production Research
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A study on setting
standard time using work
achievement quotient
Shun'Ichi Nakayama , Ken'Ichiro Nakayama &
Hiroshi Nakayama
Published online: 14 Nov 2010.
1.
Introduction
This paper proposes a method for setting a standard time using a work achievement quotient approach. As an example, the vehicle safety inspection service for
fork-lift trucks is considered. Conventionally, standard time has been set using a
Predetermined Time System (PTS) method such as the Work Factor (WF) method
(Quick et al. 1945) and the Method-Time Measurement (MTM) method (Maynard
et al. 1948), or by using a stopwatch method. The PTS method sometimes may be
inappropriate because the analysis takes too much time when it is used for a small
manufacturing volume or a long cycle time. Although simpler WF methods like the
Ready Work Factor (RWF) method, etc., have been developed, users of these methods are expected to be trained and have completed hands-on analytical practise by
receiving a formal training course and to acquire the necessary skills in order to
obtain accurate time measurements (Maynard 1963, Ikenaga 1977). When the stopwatch method is used to conduct the rating, subjective impressions can inuence the
results. To obtain accurate time measurements, a thorough training method using
Revision received May 2002.
{ Meijo University, Department of Transportation Engineering, 1-501, Shiogamaguchi
Tenpaku-ku Nagoya, Japan.
{ Sapporo University, Department of Business Administration, 3-7-3-1, Nishioka,
Toyohira-ku, Sapporo, Japan.
} Nagoya University, Department of Mechanical Engineering, Furo-cho Chikusa-ku,
Nagoya, Japan.
* To whom correspondence should be addressed. e-mail: snakaya@meijo-u.ac.jp
International Journal of Production Research ISSN 00207543 print/ISSN 1366588X online # 2002 Taylor & Francis Ltd
http://www.tandf.co.uk/journals
DOI: 10.1080/00207540210159581
3946
S. Nakayama et al.
lms, etc., is necessary. In contrast, the method for setting standard time using the
work achievement quotient approach (Nakayama and Sakai 1979a, 1979b, 1985,
Nakayama 1992, 1995, 2000, 2001) can obtain individual variations for workers in
a time sequence and evaluate it dynamically. Thus, calculation is possible using a
small statistical sample. In addition, work improvement is also possible.
The tendency equation and work achievement quotient are given here. The
tendency equation for the relation of Y to X is:
0
b
b
Y aX * 1 X :
Equation (1) has two terms: the rst gives the centre line of the tendency line, the
second the variation of the tendency. Each important index of equation (1) is determined and from the results the work performance under consideration is evaluated.
The aim of the tendency equation is to analyse the data as an area bounded by an
upper limit line and a lower limit line. The rst term of equation (1) shows the
average of the data (tendency line); the second term evaluates the rate of the accomplishment of the work, which can also be estimated from the coe cient of variation.
Here, the vehicle safety inspection service for fork-lift trucks is considered. Their
analytical results were su ciently satisfactory.
2.
Methods
The method for evaluating the performance relatively and dynamically using a
tendency equation is explained. A tendency equation is given by:
0
where
X; Y
a
b
0
b
*
1
b
b
Y aX * 1 X ;
are variables,
is a coe cient,
is the index number of tendency,
is the index number of tendency variation,
means multiply or divide,
is the initial variation.
3947
These equations are therefore used to calculate au , bu , al and bl . The coe cient a and
initial variation 1 are then determined from au and al :
0
a al au =al
1=2
and
au =al 1=2 1 :
5
6
Content of work
The vehicle safety inspection service for fork-lift trucks comprises the processes
of reception, changing the oil, washing, engine, wheels and their attaching means,
cargo, option and completed car checking. Among these, three processesthe
engine, wheels and their attaching means and the cargoare line works.
An arrangement chart for the checking maintenance is shown in gure 1. The cargo
process in the line is taken out. This process work is sorted into 14 element works. A
workers evaluation in each element work is performed and a standard time is set.
In a measurement of work time, a video tape recording (VTR) photographing is
performed to remove a measurement error. Thereafter, an analysis is performed by
reproducing the videotape and the work time is determined. The work was measured
repeatedly by 15 times.
3.1. Element works in the cargo process
The 14-element works in the cargo process are as follows.
. 1st element work: fork is lifted, safety bars are prepared and wheel stoppers are
removed.
. 2nd element work: brake liquid is supplied and the torque wrench is gripped.
. 3rd element work: nut is screwed and a hand contacts a di erential oil supply
device.
. 4th element work: supply di erential gear oil, hold a grease feeding apparatus.
. 5th element work: feed each part of the gear with grease.
. 6th element work: feed the mast rail with grease, return the grease-feeding
apparatus to the former position.
. 7th element work: start the engine, restore the safety bar and lower the fork,
hold a box-end combination wrench.
3948
S. Nakayama et al.
. 8th element work: tighten the backrest bolt, switch-hook bolt and lift-head
bolt, put the box-end combination wrench back.
. 9th element work: check and adjust the spreading condition of each chain of
the fork, hold a brush in a grease container.
. 10th element work: feed the fork rail with grease, return the brush into the
grease container.
. 11th element work: feed the brake, clutch ring and handle knob with lubricant.
. 12th element work: feed each chain of the fork with lubricant, return the
lubricant container to the former position.
. 13th element work: x the brake master.
. 14th element work: line o .
3.2. Calculation example
To demonstrate the method of analysis described, the work performance of a
worker in the 1st element work in the cargo process is considered (gure 1). A worker
evaluation in the 1st element work is performed and a standard time is set. A worker is
20 years old with 1 year of experience in the vehicle safety inspection service for fork-lift
trucks. For measurement, a VTR was used. The results are shown in gure 2.
The measured times taken by the worker for this task are plotted logarithmically
in a time sequence. Their regression line is then drawn, the direction of advance of
the data being considered. The upper limit line passing through two points on the
upper limit and the lower limit line through two points on the lower limit are
determined (gure 2). Then au , al , bu and bl are calculated from equations (3) and (4):
au 58:6653;
al 41:0965;
bu 0:0603;
bl 0:1601;
3949
Figure 2. Tendency chart of the rst element work in the cargo process.
where the coe cient a and the initial variation 1 are calculated from au and al using
equation (5):
a 49:1021
and
1 1:1948:
0
and
0
b 0:0499:
Therefore, all the parameters for the tendency equation have been determined,
giving:
8
Y 49:1021X 0:1102 * 1:1948X 0:0499;
1=2
when X 1, 1 1:1948 and Q1 1 1 1=1:1948 0:5962; when X 15,
0:0499
1:3677 and Q15 0:4815.
15 1:1948 15
The di erence between the initial ratio of variation 1 and the terminal ratio of
variation 15 is given by:
j1 15 j 0:1729:
The work achievement quotient Q for his rst element work measurement was
0.5962 (59.62%) and for the 15th 0.4815 (48.15%). (The nearer the work achievement quotient is to 1, the more competent is the worker in terms of skill.) The
variation di erence j1 15 j 0:1729 was considered as standard. The 1st element
work in the cargo process is actually applied to a tendency equation, and shown in
gure 2 (others are omitted).
The tendency equation is produced from the work time of each element work
measured in 15 times, and a work achievement quotient Q and a variation di erence
were found. And, standard values of the work achievement quotient Q and the
variation di erence are set.
S. Nakayama et al.
3950
In respective processes, the evaluation of worker is carried out, and based on the
results, the standard values for this line are set up as follows.
Work achievement quotient: 45%.
Estimated values
in X 1
Element
works
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Tendency equation
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
9
Estimated values
in X 15
Variation
di erence
Q1
15
Q15
j1 15 j
1.1948
1.2644
1.4171
1.4366
2.0102
1.2924
1.9266
1.2696
1.8793
1.5230
1.3949
2.0186
1.0692
1.5467
59.62
54.27
45.75
44.87
29.11
52.43
30.65
53.92
31.60
41.40
46.79
28.96
74.56
40.55
1.3677
1.7259
1.9161
1.5867
1.3236
1.1903
1.1933
1.2907
1.2790
1.5699
1.1863
1.6369
1.3322
1.5995
48.15
35.15
30.85
39.19
50.55
60.02
59.75
52.54
53.29
39.75
60.37
37.62
50.06
38.78
0.1729
0.4615
0.4990
0.1501
0.6866
0.1021
0.7333
0.0211
0.6003
0.0469
0.2086
0.3817
0.2630
0.0528
3951
42:77:
10
11
Figure 3. Tendency chart of the third element work in the cargo process.
3952
S. Nakayama et al.
0:0110
0:2752
Y 80:6399X
:
* 1:3355X
12
This time, the work achievement quotient is 49.88% at X1 and 52.13% at X15 , and
the variation di erence is 0.0382. These gures all meet the standard value. By
adopting the tendency equation that meets the standard value, the standard time
is set up.
Here, the standard time is calculated based on a case when the two standard
values are satised concurrently, as mentioned in the main text (this means that the
worker is nearly perfectly skilled in the work). However, the worker is required to
have completed a certain amount of training. It may look strict, but it is not specically considered as an allowance time. In this research paper, the performance
results are shown with time-series points and there are advantages in that operating
improvements can be achieved easily and the standard time can be realized more
quickly.
4.
Conclusions
The standard time was set by taking out the cargo process in the vehicle safety
inspection service for fork-lift trucks and performing its work evaluation. The vehicle safety inspection service for fork-lift trucks is a manual work, and a work whose
dispersion is large. Since the method of setting the standard time by using the
tendency equation treats the data in a time series, it is possible to investigate a
cause for the dispersion corresponding to an abnormal value so that the work can
be improved. Therefore, it is possible not only to set the standard time, but also it
becomes possible for a worker to perform the standard work faster. This method is
easy in its calculation, and the standard time can be calculated with few statistical
data.
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