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Work Measurement Techniques

Work measurement is used to determine the time required to complete one element or one. Work measurement techniques -used by garment manufacturers include

  1. Time studies
  2. Judgment 
  3. Predetermined motion time systems
  4. Standard data
  5. Operator reporting 
  6. Work sampling.
Each work measurement technique has advantages and disadvantages for specific applications.

1. Time Study
Time study is a work measurement technique commonly used by apparel engineers to determine the rate at which a specific operation is performed. The objective of a time study is to develop and check production standards. An operation is studied by time analysts while a style is in production. A time study requires a method description for the specific operation to determine the work elements involved, the order in which they occur, the time required to complete each element, and the rate at which a particular operator is working. Time studies are an appropriate method of work measurement for high-volume operations with a high degree of repetitiveness. They are frequently used to establish production standards for operations performed in a progressive bundle system.

2.  Judgment
For some apparel manufacturers, time studies may be too time- consuming and costly. For small fashion manufacturers with rapidly changing product lines and short runs or small custom orders, a style may not be in production long enough to conduct time studies. Small firms may find it economically unfeasible to employ a time study analyst. Instead, smaller firms may rely on the judgment of managers or supervisors for time estimates. This method can provide only approximate time values, and it is not advocated if there is another more accurate means of gathering the needed information.

3.  Predetermined Motion Time Systems 
Predetermined motion/time systems are used by many firms to establish production standards for new styles before the style goes into production. The basis of these systems is historic data for hundreds of replications of basic motions and elemental times that have been averaged and converted to standard times for a specific motion. This method of work measurement produces the most consistent production standards. With predetermined motion/time systems, rates are based on the time to execute a method. This forces engineers to examine equipment, layout of workstations, and handling of parts at the workstation. The method or motion sequence is established first, and the time value or rate is identified for the motions specified. Engineering specifications identify the specific method that an operator is expected to follow. Generally, this causes more effective use of direct labor and thus more accurate rates. 

There are a number of different motion-time systems. General Sewing Data (GSD), MODSEW, KARAT, and other similar systems identify time values for specific motions required in garment production. These are available as computer software that manufacturers can purchase. Engineers that use these systems must be well trained in identifying the specific motions that are involved in each operation.

4.  Standard Data
Frequently firms collect their own data for repetitive operations with similar characteristics and develop their own standard data sets for specific operations. These data are used in the same way as predetermined motion/time data except the data sets are specific to the firm’s quality standards, equipment, and procedures. A firm must have an adequate database before trying to use its own standard data. Standard data may be developed for operations, components, and styles and can be used for preliminary costing, design decisions, cost estimating, and rate setting. 

5.  Operator Reporting
Operator reporting relates to the volume completed during the time spent. Operators report the amount they complete in a specific time period. There are no specified methods or output expectations; therefore, it is difficult to use operator reporting as a basis for production standards or for capacity planning. Cost figures are determined by dividing the number of units completed in an hour with the hourly wage. The amount of work completed in a specific time frame is often inconsistent and may be unreliable. This type of work measurement provides very little information and little incentive for increasing work efficiency. It may be the method used by firms that produce customized products in small volume and wide variety.

6.  Work sampling
Work sampling is a work measurement method concerned with which machines are used and the activities pursued in executing the job in an established period of time. It is based on simple random sampling techniques derived from statistical sampling theory. When production standards are needed for operations that are not highly repetitive, work sampling is a good choice. The analyst determines the activities involved, amount of time spent on the various activities, equipment used, and number of units processed during an established time period. This type of work measurement is particularly useful in examining the productivity of non-production areas such as the shipping room. The manager can estimate the proportion of time a worker is engaged in work activity. This proportion can then be used as a performance standard.