Traditional Time Quantification
“Time Study” is a traditional method of time quantification, developed under very different business conditions than those we see today. In today's business environment there are essentially four main areas where the process of Time Study does not meet the needs of a modern manufacturer and, as a consequence, creates inaccurate and inconsistent data.
Time Consuming. A large statistical sample must be taken in order to compensate for the variability of the human worker. A one minute operation should be studied for two hours. That’s 40 hours of Time Study for a 20 minute product! Shorter studies may of course be made, but only at the cost of accuracy - and in today's highly competitive conditions this trade-off is unacceptable. With today’s short production runs and rapid product re-styling, there is often insufficient time to properly and ethically apply Time Study.
Performance Rating. A mandatory element of Time Study, Performance Rating is the adjustment of the Observed Time value, based on the Time Study practitioners subjective assessment of the operators performance. The subjectivity of Performance Rating creates inconsistency, uncertainty, disagreement and mistrust, with the consequence that operation times and targets subsequently become a matter of negotiation rather than objective analysis.
Reactive. Time Study is “reactive” in that a process cannot be timed until it is physically undertaken in the manufacturing environment – by which time product price and delivery have been agreed ! If the product cannot subsequently be made on time and/or “to cost”, profit margins will suffer, wages will be supressed and excessive overtime may follow.
Standard Methods. Time Study does not focus on standardising “method” and because operators often use different methods, the variation in Standard Minutes grows even greater, creating an inconsistent manufacturing and costing environment.