How to Conduct a Time and Motion Study with Stopwatch?

Introduction

A time and motion study with stopwatch is an industrial engineering technique used to improve the efficiency of production processes. The technique is based on the analysis of workers’ times and movements to identify bottlenecks in a production line or process. This technique is used to reduce production times, improve quality, increase productivity, and decrease costs. In this article, we will explain how to conduct a time and motion study with stopwatch.

Step 1: Preparation

Preparing the work area for a time and motion study involves ensuring that the process to be studied meets the following conditions:

• The operator perfectly masters the technique of their operation

• The method used in the process is standardized

• The employee, supervisor, and union representatives know that their activities are being analyzed

The first step in conducting a time and motion study with stopwatch is to prepare the work area. This involves cleaning the area, ensuring that all equipment is in good condition, and that materials are ready for the study. This also involves preparing the measuring equipment, such as the stopwatch, a pencil, and a notebook to record the data.

It is also possible to conduct this type of study with advanced tools for generating time and motion studies such as the mobile application for industrial time study from cronometras.com

Step 2: Definition of the Study Area

Once the work area is ready, it is necessary to define the study area, this involves selecting the process or production line to be analyzed, taking into account the following criteria:

• The potential impact of the improvement on productivity and quality

• The frequency and duration of the process

• The complexity and variability of the process

• The availability of human and material resources

• The workers who will participate in the study, the number of jobs to be performed, and the time needed to complete each task should also be identified.

Step 3: Observation and Measurement

After defining the process or production line to be studied, the work performed by the operators must be recorded and analyzed.

This involves carefully observing the tasks that make up the work and timing how long it takes to perform each of them.

To obtain accurate measurements, a stopwatch should be used and all data should be noted in a notebook; another option is to use a specialized application.

When recording data, it is important to include all relevant details, such as environmental conditions, pauses, delays, or difficulties that may affect performance.

Some aspects that should be taken into account when observing and measuring work are:

• The number of observations necessary to obtain a representative time of the work.

• The random or systematic sampling method to select observations.

• How to classify and group tasks according to their nature and frequency.

• How to apply correction factors or supplements for fatigue, delay, or special conditions.

• How to calculate the standard time of the work from the observed times and applied factors.

These aspects may vary depending on the type of work, the complexity of the process, and the objective of the study. Therefore, it is necessary to adapt to each case and follow an appropriate methodology.

Step 4: Analysis of Results

After measuring the work, the process must be evaluated and improved. This involves analyzing the data obtained and detecting bottlenecks, critical or problematic points in the process that may affect efficiency.

Solutions should also be sought to optimize production time and increase productivity without sacrificing quality.

Some solutions that can be applied to improve the process are:

• Eliminate or simplify unnecessary or redundant tasks.

• Redesign or standardize complex or variable tasks.

• Reorganize or redistribute tasks among operators or machines.

• Train or motivate operators to improve their performance.

• Incorporate technology or tools that facilitate work.

Step 5: Implementation of Improvements

Once the improvements to be implemented have been defined, it is necessary to apply them in the production line or process to improve efficiency.

This involves making the necessary changes in the tasks, resources, tools, or technology used for the work.

It also involves training workers to become familiar with the new procedures and be able to adapt to them.

Some basic actions to apply the improvements are:

• Communicate to workers the objectives and benefits of the improvements.

• Conduct pilot tests or simulations to verify the functioning of the improvements.

• Establish a schedule and budget for the implementation of the improvements.

• Monitor and evaluate the impact of the improvements on the time and productivity of the work.

• Make adjustments or corrections if necessary.

Step 6: Evaluation

Once the improvements have been applied, it is necessary to verify and follow up on the results to determine if the expected objectives have been achieved.

This involves taking measurements again to compare previous results with current results. If the results are positive, then the improvement process is considered successful.

Some basic actions to verify and follow up on the results are:

• Use performance indicators that allow measuring the productivity, quality, time, and cost of the work.

• Conduct periodic reviews to know the degree of progress and compliance with the improvements.

• Conduct trend analysis to detect if the process is improving or if there are aspects that require attention.

• Conduct earned value analysis to integrate the measures of scope, cost, and time of the process and compare them with what was initially planned.

• Make adjustments or corrections if necessary.

Conclusion

A time and motion study with stopwatch is a useful technique to improve efficiency in production lines or processes.

This technique is based on the analysis of workers’ times and movements to identify bottlenecks in a production line or process.

This helps you reduce production times, improve quality, increase productivity, and decrease costs.

Following the above steps will help you successfully conduct a time and motion study with stopwatch.

If you want to try the tool we have created to carry out this improvement process, contact us.