An introduction to the process of designing work methods – The general procedure for solving problems

In the general procedure for solving problems, three different phases can be distinguished: i) a definition phase, ii) a search phase and iii) a definition phase.

Definition phase

It consists of determining the characteristics of the problem, that is:

• The specifications of the initial and final state.
• Existing restrictions.
• The criterion (preference).
• The number of repetitions.
• The time limit.
• This includes a description of the data or constraints within which the methods analyst must operate.

Search phase

The search process implies an inquiry regarding the alternative solutions of the problem, that is, the different methods to achieve the transformation of the initial state towards the end.

This process is characterized by an investigation as exhaustive as possible, to later carry out a synthesis. In this phase, the ingenuity and inventiveness of the methods analyst plays an important role.

Decision phase

The decision process consists of evaluating the alternatives obtained, and then choosing based on the established criteria.

In practice, the aforementioned phases of the problem-solving process may have points in common, and it is often necessary to repeat the cycle, with the corresponding feedback, before finding a satisfactory solution.

An introduction to the process of designing work methods – The characteristics of a problem

What are the characteristics of a problem?

Being familiar with the characteristics of a problem is one of the foundations for its solution, since it facilitates the understanding and scope of the design and the procedure that it implies, since the design is, in essence, the solution to a problem that by tradition is entrusted to the engineers.

Solving an engineering problem, including of course related to methods engineering, involves dealing with several different methods to achieve the desired result. If there were no known or unknown alternative solutions, there would be no problem.

If all solutions were equally satisfactory, then there would not be a problem either, however this is usually not the case, since a problem involves finding a preferred method; for example, the least expensive. Therefore, if the preferred method is obvious from the beginning, there is also no problem.

In any problem there is a set of initial circumstances (input, or starting point) and a set of final circumstances (output, goal, or result for which a method is sought). The characteristics of a problem are listed below:

• The number of possible solutions is, in general, large.
• Possible solutions to a practical problem are seldom obvious at first. In reality, it is not often that all possible solutions are known in advance, even if prior analysis or research has been done.
• Alternative solutions are not equally desirable, therefore the preferred solution is sought, for which it is necessary to apply selection or decision processes. In this way, the existence of methods with different degrees of preference enables a fruitful search before making a choice. The base of the preferences is usually called the criterion and in various problems in the business world, this parameter is the profit obtained; This allows choosing the best alternative among various investment alternatives. Therefore, the method sought is the one that maximizes the profit when time, money and other resources are invested.
• The relative advantage of alternative solutions to a problem is generally not evident, and the search for data, measurements and calculations must be carried out to determine it satisfactorily. 

The cost of time and other resources dedicated to solving a problem must be considered in a reasonable way, since, as with many economic concepts, a point is reached where it is more difficult to find additional solutions and where productivity begins to decline. descend. Thus, while the search for better methods continues, a point in time is reached where better solutions are unlikely to be found that justify a greater investment of time, money, and other resources.

Can a problem be solved perfectly?

There are two reasons why a problem cannot be solved perfectly: i) the time required for such a task would be greater than the life of the problem, which is true for the vast majority of problems in the industry and ii) it is not economically optimal to try to find a perfect solution. It is more economical to direct efforts to other problems that require solutions, before continuing to try to find a perfect solution.

In solving problems, it is not intended to find one that is completely ideal, nor is it expected to find it, since there would be no possibility of recognizing it as such if it were found. The idea that is pursued is to progress towards the ideal solution, looking for better solutions until it is determined that it is not productive to continue with the search.

Methods engineering

It includes designing, creating and selecting the best manufacturing methods, processes, tools, equipment, and skills to manufacture a product. When the best method interacts with the best skills and efficient worker-machine relationship exists. Of course, when one method is established, then a standard time for the product can be determined. 

Methods engineering definition

We can define methods engineering as the technique for increasing the production per unit of time or decreasing the cost per unit output. Alternatively, it can be viewed as the technique that looks for productivity improvement.
Method engineering implies the following during the history of a product:

• It is responsible for the design of the work center where the product will be produced;
• It is responsible for the continuous improvement of the work center with the purpose of find a better way to produce the product or improve its quality. This analysis is also called corporate reengineering.
• Methods engineering is in constant development because of the technological evolution. In this sense, the improvements in productivity are never ends. Research and development is therefore essential to methods engineering.

The procedure of methods engineering

• Select the project
• Get and present the data
• Analyze de data
• Develop the ideal method
• Present and install the method
• Develop a job evaluation
• Establish time standards
• Follow up the method

Productivity, types of productivity, productivity index, total productivity

Whats is productivity?

Productivity is the ratio of output to some or all of the resources used to produce the output.

Types of productivity

We can mention the following types of partial productivities:

• Labor productivity: units produced / hours worked
• Capital productivity: output / capital input
• Material productivity: output /material input

What is the productivity index?

We can calculate a type of partial productivity as labor productivity as output per man hours for a complete year. These figures obtained from year to year can be indexed and can be related to a base year so that output per man our comparisons can be made.

Definition of total productivity

It is the ratio of tangible output and tangible input.

Differences among partial productivity, total factor productivity and total productivity

Men, materials, machines, methods, money, energy, etc. are inputs.

• Partial productivity: output / one class of input
• Total factor productivity: net output / (labor + capital)
• Total productivity : sum of all tangible outputs / sum of all tangible inputs

Methods design, motion and time study

What’s methods design

Methods design is the analysis of the various ways a task can be done so as to establish the one best way. It includes motion analysis (the study of the actions the operator can use and the advantages and/or disadvantages of each variation) and standardization of procedure (the selection and recording of the selected and authorized work methods).

While ‘‘time and motion study’’ is the more commonly used term, it is more correct to use ‘‘motion and time study,’’ as the motion study to establish the standard procedure must be done prior to the establishment of a standard time to perform that work.

Motion study definition

Motion study can be defined as “the analysis of the manual and the eye movements occurring in an operation or work cycle for the purpose of eliminating wasted movements and establishing a better sequence and coordination of movements.”

Time study definition

Time study can be defined as “the procedure by which the actual elapsed time for performing an operation or subdivisions or elements thereof is determined by the use of a suitable timing device and recorded. The procedure usually but not always includes the adjustment of the actual time as the result of performance rating to derive the time which should be required to perform the task by a workman working at a standard pace and following a standard method under standard conditions.”

Attempts have been made to separate the two functions and to assign each to a specialist. Although motion study deals with method and time study deals with time, the two are nearly inseparable in practical application work. The method determines the time required, and the time determines which of two or more methods is the best. It has, therefore, been found best to have both functions handled by the same individual.