Time study for operations is a systematic method used to analyse the time required to perform a specific task or process within an operational environment. The primary goal of a time study is to identify how long it takes to complete a task, understand the variations in task performance, and pinpoint opportunities for improving efficiency and productivity.
Successful Time Study Requires Proper Planning and Preparation
Define Objectives
Clarify Goals: Determine what you want to achieve with the time study. It could be reducing cycle time, increasing efficiency, or identifying bottlenecks.
Identify the Process: Specify the process or task to be studied. Be clear about the boundaries and scope.
Use Appropriate Methodology
Stopwatch Method: Measure the time taken for each task using a stopwatch. Suitable for simple tasks or when you need a quick estimate.
Work Sampling: Record random observations over time to estimate the percentage of time spent on different activities. Useful for tasks with variable times.
Time and Motion Study: Analyze both the time and movements involved in a task. This method is more detailed and often used in manufacturing.
Data Collection
Record Time: Use your chosen method to record the time taken for each step or iteration of the process. Ensure measurements are taken under normal working conditions.
Observe Variability: Note any variations in time due to different factors (e.g., skill levels, equipment condition).
Data Analysis
Calculate Averages: Compute the average time for each task or step. Identify any significant deviations.
Identify Bottlenecks: Look for stages where time is longer than expected. These are potential areas for improvement.
Compare with Standards: Benchmark against industry standards or best practices to gauge performance.
Identify Improvement Opportunities
Eliminate Waste: Focus on reducing time spent on non-value-adding activities.
Standardize Procedures: Develop standard operating procedures to ensure consistency and efficiency.
Optimize Workflows: Re-organise tasks or workflows to minimise delays and unnecessary movements.
Implement Changes
Test Improvements: Pilot changes on a small scale to see if they lead to the desired improvements.
Train Employees: Ensure that all relevant personnel are trained in new procedures or techniques.
Monitor and Review
Track Performance: Continue to monitor the process to ensure that improvements are sustained.
Adjust as Needed: Be prepared to make further adjustments based on ongoing performance data and feedback.
Document and Share Findings
Record Changes: Document the improvements made, including any new procedures or practices.
Share Successes: Communicate the results with the team and other stakeholders to reinforce the benefits of the changes.
In a fulfilment warehouse, time-study can be performed on:
Inbound Processing
Put to Shelf
Pick and Pack
Order Consolidation
Leveraging on time study analysis, organisations can drive continuous process improvement, enhance operational efficiency, and ultimately achieve better performance and competitive advantage.
But What Exactly Can We Gain from Time Studies?
Identify Inefficiencies
Cycle Time Analysis: By measuring the time taken to complete each task in a process, time studies reveal which tasks are consuming more time than expected. This helps in pinpointing where inefficiencies lie with a cycle time analysis. Insights on task durations helps the team to understand variances in performance, highlighting where processes are slower than they should be.
Pinpoint Inefficient Activities
Many organisations are looking at ways to minimise waste in an effort to build a more sustainable ecosystem with circular economy in mind. Time studies help identify activities that do not add value from the customer's perspective where wastages can be identified. These non-value-added activities can be targeted for elimination or reduction. By isolating tasks that consume time without contributing to the end goal, organisations can further streamline processes to focus on activities that enhance value.
Spotting Redundancies
Detailed time studies often lead to insights into redundant steps or activities that overlap or duplicate efforts in process mappings. This lead to workflow optimisation where removal of redundant tasks can simplify workflows, leading to faster and more efficient processes.
Uncovering Bottlenecks and Enhancing Efficiencies
Time studies help identify stages in a process where work is delayed or slowed down. Performance bottlenecks can be addressed to improve overall flow and reduce lead times. Understanding where bottlenecks occur enables better allocation of resources to critical areas, thereby improving throughput. Organisations can drive continuous process improvement, enhance operational efficiency, and ultimately achieve better performance and competitive advantage.
Empowering Process Improvement Teams
In our VUCA world, data-driven decisions is more important than ever. Time study analysis provides concrete data that process improvement teams can use to make informed decisions about where and how to implement changes. Actionable insights from time study granular data helps in formulating targeted strategies for process optimization and waste reduction.
Conclusion
If you are looking at time analysis for your organisation, chances are you are looking at continuous improvement methods to drive operational excellence. It is important to note that time studies are not a one-time exercise but part of an ongoing effort to monitor and improve processes.
Regular time studies help in sustaining improvements and identifying new areas for enhancement. Such continuous analysis allows for a feedback loop where processes are constantly refined based on performance data.