dries, L. S. Ayres & Co., City Ice and Fuel Co., Sayco V~lve Corp., Hotel. Sherman, and many others. I am further ..
MOTION AND TIME STUDY II
!J II
MARVIN E. MUNDEL, Ph.D. Director, M. E. Mllndel & Associates Indllstrial Engineers M ilu:aukee, Wisconsin
MOTION
".
•
Ii
THIRD EDiTION
PRENTICE-HALL, Inc. Englewood Cliffs, N./. 1960
Motion and Time Study: Principles and Practice, Third Edition, by Marvin E. Mundel
© 1950, 1955, 1960 by ~~.ll'\.o. PRENTICE-HALL, INC.
Englewood Cliffs, N.J.
10 I
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All rights reserved. No part of this book may be reproduced in any form, by mimeo. graph or any other means, without permission in writing from the publishers.
Printed in the United Stat{-'
of America
Library of Congre~s Catalog' Card No.: 60-7837 60302-C
~
Preface to the
third edition •
•
•
As ~ith the previous editions, in revising this book, I have sought to maintain the concept of a systematic, practical, and yet scientifically correct treatment of the subject. The cognitive processes of using these materials are included to aid in a full understanding of the materials. The new materials have been carefully evaluated in ,actual working situations to determine the desirability of including them in this edition. "Vhere applicable, statistical analyses have been introduced in the form in which they are used in industrial plants. The connection of motion and time study to the newer industrial engineering techniques involving math~matical models has been indicated where appropriate. In the interval between the second edition and this revision, I have had an opportunity to verify at first hand the applicab~lity of these techniques to industrial situations in England, Germany, Sweden, and Japan, and discussed them 'further with colleagues and former students who have cahied them to India, Taiwan, Norway, Israel, and Australia. The sections on time study have been almost completely rewritten not! only for greater clarity, but also to reflect the extensive industrial applications made during the past five years. Those items which were suggestions in the first edition and isolated examples in the second edition have, in the interim, been applied so widely, I have .been able to cite extended and varied illustrations to assist in guiding the practitioner. v
vi
.PREFACE
In revising this book I am deeply indebted to Mr. C. J. Allen of Patrick Cudahy, Inc., who has so magnificently cooperated in maintaining a thorough statistical analysis of the results of an industrial application of the objective time study technique for six years. I am also indebted to Mr. L. Pie I of Johnson Service Co., Mr. C. DeWitt and Mr. G. Kaplan of Western Printing and Lithographing Co.,. Mr. R. Amstutz, Mr. A. Mandele and Mr. M. Ottow of the S & C Electric Co., the industrial engineering staff of S. C. Johnson Co., Mr. F. Pleva of Herbst Shoe Co., Mr. E. Syhendel of Trostel· Leather Co., Mr. A. Erickson of BarberColman Co., Mr. J. Ruedebusch and Mr. G. Ploger of Mirra Aluminum Co., Mr. A. T. Tseng and Mr. J. Carpenter of the Diamond-Gardner Corp., Mr. R. Klockzim of Inland Steel Co., Mr. Lacey Randolph of' the American Steel Foundries, and Mr. R. Belt of Hamilton Manufacturing Co., for their cooperation on applications which are reflected either in examples in this edition or in the approach to various problems treated in this book. Mr. W. Shallman and Mr. R. Thelwell of the Army Ordnance Corps Management Training Agency, Mr. W. Spooner and Commander Guinn of the Navy Bureau of Ships, Mr. John Blake of the Long Beach Naval Shipyard, Mr. M. Peal of Beneda Arsenal, and Col. J. MacGruder of the Air Force Advanced Logistics School have all influenced the making of this revision. To my associate, Mr. Norman Kobert, I owe much for the many hours of discussion on some new aspects portrayed here. Also, thanks are due Prof. W. J. Richardson of Lehigh University who has been a constant source of suggestions. To Mr. B. Carlberg,. Mr. L. Fahlinl Mr. L. Rask, Prof. R. Kristensson and Mr. Yngve Svensson of Sweaen, I am deeply indebted for their. assistance, cooperation and advice on much presented in this book. Like- wi~e to Anne Shaw (Mrs. J.. Pirie), Mr. R. M. Currie, Mr. P. B. R. Gibson, Mr. R. Connelly and Nl,r. W. Rodgers of Great Britain, Mr. A. Taka- naka, Mr. N. Isogai, Mr. T: Harada, Mr: K. Yoneda a~d Mr. S. Sakai of Japan, and Prof. H. H. Hilf of West Germany. So much of what is presented has been deeply influenced by an those with whom I have worked that sufficient thanks are difficult to express. Thanks are c~rtainly also due 'my secretary, Mr~. Van Altena, who ' did all the typing on this manuscript. It is my hope that in assembling these materials I have moved our base of operations forward and provided a new locus from which we may progress. Also, I hope that this book will allow these procedures, founded so heavily on the pioneer efforts of Frank B. and Lillian Gilbreth, to more funy serve mankind, as these pioneers intended.
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Preface to the second edition
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The guiding principle in this revision has been to rna ~~\t~ - ..:. 'I- -' .....::. cept of a systematic, practical, and yet scientifically corre~;~~'in:n~.:~-::' _,I.......~:f ' present-day motion and time study, Care has been exercised~ ~ntliillel.' ~, ' new materials covering more recently developed approaches to' rob: .. ,' lems where the new approach represents a distinct contribution t~ the field. As in the original edition, the new materials are examined from their fundamentals so that they can be understood rather than a li d e as routine procedures. The illustrations that have been added, likePfho in the first edition, have been kept in the form in which they wou;~ appear in practice, so that they may continue to provide Working g 'd U1 es. In the interval between the release of the first edition and this r eVlslon, ,. I have had an opportunity to test the materials further, not onl 'tl . , .. Y WI 1 several thousand college students but also WIth IndIVIduals from a wid variety of industries. I have also discussed the materials with praCt'ICIng . e industrial engineers and teachers from many countries.• On the b aSIS' 0 f these experiences I have attempted to clarify the concepts in this bo k During this interval I also served under the Fulbright Program ~' as VISiting lecturer at the University of Birmingham, England. There , through the good offices of Professor T. U. Matthew, I met numerous Brl't'IS) 1 In. / dustrial engineers and toured many British plants. The opportunities f study and discussion which the visit made possible are reflected in th~: revision., More recently I undertook to organize and operate on a national basis a manage!TIent engin~ering training program for ~~e, United States Army Ordnance Corps, whICh employs over 160,000 CIVIlIans. The tech' .. · d llIques of motion an d time stu y ' played an important part in this pI'ogram and the opportunity to worf with these techniques on such a Wide scal ' has influenced the thinking: throughout this new edition. e In planning this book I ;am indebted for suggestions or material t many people in Great Britain, particularly to Miss Anne G . Sh aw 0Of I the Anne G. Shaw Organi'1ation, Mr. F. Garner and Mr. W. E. Smith of Lucas Ltd., Professor T. U. Matthew of the University of B' . lrmmgham, Mr. R. M. Currie (a~d his staff) of the Imperial ChemIcal Industries, Mr. P. B. R. Gibson oRthe REMC, Professors Connelly and W'l h' l I S Ire of the College, of Aeronautics, and Mr. Winston Rodgers of the De tment of Scientific and Industrial Research. But this list is far from par complete. , I am also indebted to Mr. Bo Casten Carlberg of Stockholm, Swed and the many Swedis.h industrialists he introduced me to, to }.rr H enn ~n: . 'Vi. Dubois of Fabelta, Belgmm, and ttJ many members of the staff of Le
viii
PREFACE
Bureau de Temps E:Zementaire in Paris, France, for their willingness to exchange material and to discuss alternative approaches to problems in the field. Of special assistance were the discussions with my colleagues in the Ordnance Corps, particularly Dr. Irwin Lazarus (who prepared so much of the material in Chapter 26), Mr. Joe Moquin, and Mr. C. F. Schneider, as well as the hundreds of practicing analysts with whom we worked. Further, this revision reflects applications made possible through the cooperation of Mr. Glenn Wolfe of the A. O. Smith Corporation, Mr. C. Allen of Cudahy Bros. Co., and Mr. Robert Prosser of the Milwaukee Gas Light Co. Thanks are also due to my former associate, Professor W. J. Richardson, who offered many worth-while and detailed suggestions. The list of names only begins to indicate all those who have influenced this new edition. As with the first edition, I hope they are pteased with the result.
II Preface to the first edition This book is intended to provide a systematic, practical, and yet scientifically correct treatment of present-day motion and time study. Rather than include a description of everything that has been done, regardless of .relative merit or value, my aim has been to present in organized form the basic principles pervading successful work. The development of these principles is examined so that they may be understood and applied naturally rather than as clerical procedures. Illustrative examples are given in great detail so that the highly important reasoning prooesses involved in the application of the procedures are discernible. The numerous illustrations have been- chosen so that those in each chapter begin with a simple case, and proceed in an orderly fashion through cases of increasing complexity, to acquaipt the reader fully with the 'approach to most of the ,types of problems he may e'ncounter. At the same time, they have been chosen from a ~ide variety -of industries and types of work to demonstrate the similarity and feasibility of applying motion and time study to all kinds of activiti~s. The graphic analyses u·sed in the ii)ustrative problems are presented in the form in' which they would normqlly ;ppear in practice so 'as to provide a working guide. The extensive problerh'section offers adequate practice opportunity. In writing this book I.have drawn fl:eely on the background provided by the pioneer work of Frank B. and Lillian M. Gilbreth and on the teaching of the man who istarted me in this field, Professor David B. Porter of New York University. The influence of Lillian M. Gilbreth, a colleague during my first six years at Purdue, has also been profound.
PREFACE
ix
In addition, I have drawn on the research I did at the University of Iowa and on my experiences in industry. Research performed by various students at the Purdue University Motion and Time Study Laboratory has 'been used to fill out gaps in previous knowledge, and the debt is indicated in footnotes throughout the text. The method of presentation and the material have been checked through use in university classes and in-plant training courses for groups ranging from top' management to foremen. Previous work with industrial engineers, foremen, union stewards, and workers, as well as the work of applying motion and time study to naval operations and the special training courses I conducted for research and extension workers in the field of agriculhue and home economics, was of great value in checking the significance of new experiences. lowe much to the cooperation given my activities over the years by L. P. Persing of the General Electric Co., Dean Parsons of the Perfect Circle Co., J. F. Rittenhouse, Jr., and F. Savage of C. G. Conn, Ltd., L. J. Fletcher of the Caterpillar Tractor Co., John Harder of R. G. LeTourneau, Inc., Claude Campbell and Guy Avery of Acme Steel Co., Guy Bates of· General Motors Corp., and Charles Winkleman of Belden Mfg. Co. More recent opportunities were presented by C. Elliot of the Pharmaceutical Survey; also numerous individuals affiliated with Servel, Inc., particularly H. Straus of that organization; also American Steel Foundries, L. S. Ayres & Co., City Ice and Fuel Co., Sayco V~lve Corp., Hotel Sherman, and many others. I am further indebted to A. K. Branham of the Purdue University Division of Technical Extension, who encouraged me in producing a former book, Syste1T!.atic M atian and Time Study, and offered many suggestions during the preparation of the present book. My gratitude also to H. T. Amrine, W. Holder, O. S. Hulley, G. Nadler, and W. J. Richardson, colleagues who offered much valuable criticism while the first book was in use. Thanks are due also to the many other readers who constructivel~ criticized the first book. Further thanks are due A. H. Callander, who: painstakingly prepared most of the illustrations for this edition, and to both Mrs. C. Marshall and Mrs. A. E. Ball, who so graciously typed inost of the actual manuscript. In short this book represents contributi6ns from many sources, and I sincerely hope that those who participa.te,d are pleased with the . (E
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Contents
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What motion and time study can accomplish 2
The human factor
1 19
3
The scope of ,motion and time study
26
4
How to start the analysis
33
5
Process chart-product analysis
53
6
Process chart-man analysis
99
7
Work activity analysis and work sampling
139
8
Process chart-combined analysis
160
9
Operation charts
189
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Multiple-activity an?'ysis-man and machine charts
216
Multiple-activity analysis'-multim_?n charts
241
12
Micromotion study
255
13
Micromotion study and therbligs
275
14
Memomotion study
301
15
Cyclegraphic and chronocyclegraphic analysis
317
16
Motion economy
321
17
Time study-introduction
325
11
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•••
18
Dir~ct
time study-definition of standard
333
time 19
Direct time study-recording the standard 340 practice
20
Direct time study-recording the time values
21 22
Direct time study-rating
23 24 25
Direct time study-objective rating
26 27 28 29
Direct time study-effort rating / Direct time study-allowances Synthesized time standards-elemental l"7e ¥D
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