Work Measurement PFC & Time Study Webinar

[Audio] Hello everyone, and welcome to the global Industrial Engineering webinar series. The Global IE team is presenting a series of 7 LIVE webinars to re-enforce foundational IE practices to all engineers of all levels; and, to introduce this as new material to our new engineers as well. As a reminder, all presentations will be given in English… we kindly ask you to convey this information to those that will need it in your local languages. My name is (SAY YOUR NAME) and will be your presenter today. The experts onboard are (LIST THEIR NAMES). They will help answering any question you may have during the presentation by using the Q&A chatbox in the upper right corner of your screen. Our LIVE Q&A session will take on additional questions right after the presentation, and we will feature several questions so all may see and hear our response. This LIVE event is being recorded! The recording and powerpoint slides will be available in about a week in the IE Portal. In the unfortunate event of a network connection issue, you will still be able to download the recording and watch it. Additionally, all of the Q&A questions will be recorded as well. Today we will focus on Work Measurement, PF&D Allowances… thank you for joining, and we will now begin. CLICK TO NEXT SLIDE.

[Audio] In this webinar we will explain the definition of Personal Fatigue and Delay Allowances, or PF&D, and it's importance. The relationship with the Standard Time. And we will dive into the factors of PF&D and how they are calculated..

[Audio] During any workday people do not work continuously. People engage in activities that are not directly task-related, or stop working entirely due to various causes. Such non-working periods are, for example, visiting a restroom, resting to overcome fatigue, talking to supervisor or colleague, assisting a restock of parts, etc. Although these examples may not affect the operator building each individual unit, these examples are required for the operator to perform their jobs over a full shift. We must consider these non-working periods to develop our standard time. Therefore, we will need an objective assessment of the allowances that can be consistently applied to the various elements of work. Personal, Fatigue, and Delay, or PF&D, Allowance is added to the Normal time, to create our standard time, that allows, over the duration of a shift, the operator the opportunity to recover from Physiological Fatigue, or physical factors Psychological Fatigue, or mental strain And to give the operators time for Personal needs.

[Audio] Work measurement tools (like a Time Study or MOST) produce normal times; these do not cover all of the time a worker is paid for, or for which consideration must be given for planning and scheduling purposes due to fatigue; A time study or a MOST only produces the Normal time of the total work content; The PF&D Allowance is necessary to get the Standard Time. The standard time allows a normal operator to achieve, on a regular basis, under normal operational conditions, a consistent time to complete each unit produced. A PF&D Allowance, or percentage, is given to take care of the following factors representing non-working time: P for Personal needs (for example a toilet break…) F for Fatigue (Rest pauses to reduce tiredness) And D for Delays (because of small unavoidable interruptions) Not All Non working times are considered under Allowance. Non working time due to worker Inefficiency, machine down, a tool is broken, test failures, or having other specified assignable causes (downtimes) SHOULD NOT be considered as part of PF&D Allowance; Let's have a look at these factors one by one:.

[Audio] The first element, P, stands for the Personal need allowance, and is always present in any manual work environment. Personal need allowance does not vary with the type of task being performed; It takes care of the necessity to leave the workplace for some personal needs, such as washing, going to lavatory, getting a drink, or similar… But normally it is fixed for all tasks/operations in the firm or organization, because they are integrated in the break schedule. Personal Need Allowances is normally given in the form of short breaks or rest pauses of 10 to 15 minutes each. They can be calculated in detail for each site, but are usually around 5[break]% Note: Lunch breaks (up-to-30mins) are not part of the Personal Need Allowance. We will touch on this more later in this webinar,.

[Audio] The second element, F, is the Fatigue allowance. Every manual work needs energy. Continuous working for a longer period causes fatigue. Hence we need some compensation in time to recover from fatigue to come back to the normal level of work efficiency. This is termed as Fatigue Allowance. Fatigue allowance is given for manual work ONLY. There is NO Fatigue allowance for a Machine controlled work element. It is not necessary that every work create fatigue. Depending upon the type of work, the energy (rate of work) spent varies, so does the Fatigue Allowance %. The fatigue allowance is normally greater than 5% in Jabil. This is a good moment to reference our previous Ergonomics webinar… if we create a good ergonomic environment and workstation, we can lower the percentage of fatigue allowances. Thus, our overall standard time will be reduced while making the work environment safer..

[Audio] And Finally, D, represents the Minor Delay Allowance factor. Delays, or interruptions, of short nature which occur over a work day are accounted for giving a certain % allowance to the normal time. In a Standard Day work, only those delays which are random and short generally <1.5 mins in nature are accounted; Examples are: Talking to a line manager or material handler, picking up dropped components during operation, etc… Downtimes are not included in these Delays. They are not part of the Standard. These are things like a machine is down, or a tool is broken, or the wrong material came out, etc. To calculate it to a greater accuracy it is suggested to do a random sampling over a longer period covering different shifts and different days in a week. In Jabil, we will always normally apply just 1%..

[Audio] These applicable PF&D allowances should look familiar to those who joined the first Time study Webinar. It shows the applicable PF&D percentages for the most common Jabil processes. USE LASER POINTER – explain each example Now, we explain the details how these are calculated..

[Audio] The Determination of PF&D Allowance is the most controversial part of the Work study. In Jabil, we will base our definition on an objective assessment of the Allowance which can be consistently applied to the various work factors. Modern day methodology as mentioned in Maynard Handbook & Institute of Industrial Engineers Handbook suggest to initially derive P&F together as one percentage by taking reference to ILO (International Labour Organization) guide lines. Jabil is advocating the same which is mentioned in 4th Edition of ILO Manual "Introduction to Work Study" The Rational behind combining P&F to specify as one % comes from the fact that, when breaks are taken as part of Personal Need, this will then allow the operator to recover from his or her work fatigue. In other words, if I am on break, then my body and mind can rest and recover; and I can return to work more refreshed..

[Audio] The International Labor Organization guide line is a bit tedious, but it is comprehensive to derive at the % for PF&D allowance. There are many fatigue causing factors being considered while deriving the P&F percentage allowance. There are 3 groups: Physical Strain Mental Strain, and Environmental Strain. Each group has several factors to consider. Determining the Strain Points for each factor will allow us to define the Personal and Fatigue part of the Allowance percentage. And, as a reminder, D, delay, will just have 1[break]% We will walk through each one of them together..

[Audio] For calculating the Strain Points based on Average Force we can use Table 1. This Table has 3 types of force categories: - Push Points (Pushing/pulling a cart or material, pressing a foot pedal, carrying a load) - Carry Points (moving material in air above the knee level) - Lift Points (Lifting material from floor or below knee level) The next slide will explain this more….

[Audio] Let's have a look at an example representing an Assembly Station, where an operator is pushing a 30kg printer for 6 sec on a trolley. Collect and insert light components for 15 sec and then tightens a bolt for 9 sec with a force of 2kg. To know what weight to consider in the table, we need to calculate the weighted Average force used in each step of the operation. The push force = 30kg multiplied with a friction coefficient of 0.15 gives us 4.5kg. Now we have to factor in the other work elements of the operator's work and perform a weighted average of force calculation…. (USE LASER POINTER – describe weighted average numbers…) This gives us a total of 1.6kg, which is less than 2 kg. For forces up-to 2 kg, we see in the table that 5 Strain Points need to be assigned to this average force physical strain. This seems like a lot of calculation to find one number in a table, but as you will see in a summary at the end of this webinar, the forces we normally use in Jabil are often quite low. But, for special cases, we can adjust by using this table as a guideline. You may note that for weights or forces up-to 1 kg the Strain points for Average force is "0"… which is quite common in jabil..

[Audio] For the next Strain Point, we do not need to calculate anything, so this will be easier. The factor we are scoring here is Posture (or how the body is positioned during the activities, like sitting or standing or bending…) Here we just need to select the correct category that fits the situation, and assign the corresponding strain points to the posture factor in the table. For our operation, we are standing with a small load, so 6 points is given. A note: For "6" points we will consider only when there is a load of > 1 kg of effective load; Taking material using cart or trolley will NOT fall under this category.

[Audio] Next Factor is Vibration. To assign point, we simply look at the table and choose the situation the best applies to the task being performed. If nothing applies, then we assign 0 points. For most of Jabil's processes this strain point is "0"… even an electric torque driver with a high setting would be 0. However, a portable power drill can exist in some operations which would then be 4 points..

[Audio] The length of the repetitive cycle time also defines some points. The shorter the cycle time, then the more points. To be clear with this table, cycle time means the beginning of the task to the end of the task, and not from individual work elements within the rask. Looking at table 4 this means any Cycle time > 10.5 sec should not call for Short Cycle strain points. This is very common for manual operations inside of Jabil..

[Audio] The last Physical Strain to consider is whether the operator is hindered by restrictive clothing. In a standard Jabil production environment, mostly this is "0" again. Again, since no descriptions apply, it is ok to use 0 points. (USE LASER POINTER) Often in Jabil we are required to wear gloves and this would result in 1 point being assigned. Another case in Jabil, are operations in conformal coating where the operator is required to manually spray the products – much protective and restrictive clothing is required here; thus 8 points would be appropriate. And Because a Clean Room clothing is very light, it is not classified under Restrictive clothing, and 0 points is appropriate..

[Audio] The next group of factors will fall under the Mental Strain group. The first factor is Concentration, and is more related to the attention required by the operator while doing the activity. For routine, and simple assembly processes, we assign 0 points. (USE LASER POINTER) In Jabil, we could use several allowance points in this table… for example, 1 point would be given for packing operations that have a lot of material; 5 points for manual inspection processes; or even 7 points if the inspection operator is using a microscope for detailed inspection points. if Poka Yoke solutions are in place, it can relieve concentration..

[Audio] The next factor is the level or degree of Monotony, or how repetitive or even how 'boring' an operation is, will provide us with the next Mental Strain points. In a general assembly line case, 5 points is selected. (LASER POINTER) In this table, we can see that 6 points might be selected for routine inspections; and even 11 points for an operator working by themselves on a highly repetitive task – a job can become quite monotonous without peer around you for an extended period of time… if this is the case, allowing music is a great way to alleviate monotony..

[Audio] Eye Strain considers the lighting conditions, the amount of brightness, reflectiveness, flickering and so on. In most of Jabil assembly operations, this should be assigned 0 points. (USE LASER POINTER) As you can see in this chart, Jabil may use several different allowance points… 2 points for simple inspection, 4 points for more detailed inspections. For extremely detailed solder operations that use a magnifying glass, you may even assign 14 points..

[Audio] The level of noise is also something to keep in mind, and depends on the work cell or area you are working at. For our general manufacturing floors, we will often assign 1 point. While our manufacturing floor is probably not near busy traffic, the concept of noisiness from traffic can be relatable to our production floor. (USE LASER POINTER) As you may know, Jabil can have some very loud operations… you may assign 2 allowance points for a noisy machine; a loud server room could be at 4 points… anything 4 and above, would likely require the use of ear protection. For most of Jabil EMS plants this strain point is "1" or very low..

[Audio] The Final group of factors is related to the environment of the production area. Here we will look at the Temperature & humidity, wetness of the area, and the air ventilation. As noted in the ergonomics webinar, these three factors are controlled to comfortable conditions across the manufacturing floors. Each factor will normally be assign 0 points. For most of Jabil's EMS plants this strain point is "0" again..

[Audio] And finally for environmental strain, Dust, Dirt and Fumes also can have an impact on operators that are working. On our manufacturing floors we upkeep good 5S practices, and these three factors generally do not affect our manufacturing floor; thus, we will assign 0 points for each factor. The factor, Fumes, may have 1 point assigned for soldering operations, or certain manual conformal coating fumes. To note, for Jabil, most of the EMS plants will have 0 points assigned here..

[Audio] Now we have all our Strain Points, we take the sum and calculate the total of 17 strain points for this example. Table 12 should be used to find how much % for P&F we need to use. We first look at the 10 of the total strain points, and cross reference that with the 7 of the total strain points… and where the two intersect will be the total P and F allowance…. As seen here, this the P&F allowance is 12%. Values are PF percentages in table 12, and include 5% of Personal time P. This is where it is good to read the fine print… in other words, this calculated 12% includes 5% personal time for coffee breaks, etc..

[Audio] Now we can calculate the total PF&D%: Our example gave a PF Allowance result of 12[break]% As we saw in the Strain Point to allowance % Conversion Table, the Minimum PF allowance that can be given is 10%. Next we should add some percentage for minor Delays. Normally D can not be more than 2%. In case if there is no detailed study done, it is safe to assume D is equal to 1.0[break]% So the Total PF&D Allowance at this moment will be 12 + 1 = 13[break]% This is excluding lunch break, but including short breaks. Because mostly we do not expect output during breaks, This is NOT the PF&D% to be applied at Jabil! This includes the break times, we need to exclude from the %. Lets see how that affects our calculation….

[Audio] Remember the fine print that P&F includes 5%? We will now explain why we need to remove it from the Total PF&D% to get what is called the Applicable PF&D%. Rest Breaks are given to allow the operator to recover from fatigue or to attend to their personal needs. Since P&F were derived together, and the table includes 5% for P… we need to remove the 5%. Therefore, 13% minus 5% comes out to 8%. This 8% is the applicable PF&D% that we should add to our normal time to get the standard times. Even though the table says 5%, that number is actually calculated based on breaks and lunches during the shift. In other words, based on your site's time allocated to lunch and breaks, your applicable PF&D% could be slightly different for the same task. Here is how to calculate for the P%... (USE LASER POINTER) The equation is your break time over your shift time minus the lunch time. You multiply this number by 1 + the total PF&D, which in this case was 13%. So, if we have a break time of 20 minutes, an 8 hr shift (or 480 minutes), and a lunch break of 30 minutes… we solve the equation to 5.02%. Since many shift, breaks, and lunches vary from site to site, the P% value that you subtract away from the total PF&D will always be slightly different. However, the P% will normally be between 4 and 6%, with about 5% being the most common. Small remark: Any Lunch break taken beyond 30 minutes can be considered as part of Rest Break/Pause.

[Audio] For you information, Here are the calculated recommended allowance percentages for typical operations most common in Jabil's different manufacturing sites. This template can be found in the IE Portal. This is based on the assumption that the shift time is 480 minutes, with a 30 minutes of Lunch Break and 20 minutes of scheduled other breaks. However, in the attached excel template you can change these accordingly. (USE LASER POINTER AND DESCRIBE A FEW OF THE COMMON PROCESSES) Remember, As a rule of thumb: the Applicable PF&D% is the Total PF&D% minus 5[break]%.

[Audio] This concludes the Webinar where we explained to you the definition of PF&D Allowance and it's importance. That non-working times are an opportunity for the operator to recover. To get the Standard Time, we need to add the PF&D Allowance percentage to the Normal Time. We explained the elements of P, F and D, and how P&F is derived from physical, mental, and environmental strain factors. Which leads us to calculated the Applicable PF&D% in Jabil specific cases. Remember to use the Applicable PF&D% instead of the Total PF&D%. As a final reminder, downtime events are not considered as part of the PF&D percentage.

[Audio] Before leaving, we would like to thank you for your participation, and remind you that all the webinars will become available on the IE Portal. More detailed IE training modules will be available through Workday..