1. What is method study?
Method study is the systematic recording and critical examination of the existing and proposed way of doing work so that a better and more effective method can be developed. In simple words, method study means finding the best way to do a job.
Very easy meaning
Imagine a worker is packing products.
The worker:
- walks too far to get the material
- bends again and again
- searches for tools every time
- repeats some unnecessary steps
Now suppose the workplace is rearranged:
- material is kept nearby
- tools are placed properly
- movements are reduced
- the steps are simplified
The same job becomes faster, easier, and cheaper.
That improvement in the way of doing the job is called method study.
2. Why method study is important
Method study is important because many jobs are done in inefficient ways without people realizing it.
A poor method can cause:
- unnecessary movement
- extra time
- worker fatigue
- machine waiting
- more cost
- low productivity
A good method can:
- reduce waste
- improve flow of work
- reduce effort
- improve safety
- increase output
- lower cost
So method study is used to improve the way the work is performed.
3. Main objective of method study
The main objective of method study is to develop the simplest, safest, fastest, and most economical method of doing a job.
This means method study tries to:
- eliminate unnecessary work
- combine useful steps
- rearrange the sequence of work
- simplify operations
- reduce fatigue
- improve productivity
So the goal is not just speed. The goal is better work performance overall.
4. Method study as part of work study
Method study is one of the two main parts of work study.
Work study has two major parts:
- method study
- work measurement
Method study deals with the best method.
Work measurement deals with the time required.
So:
- Method Study = best way
- Work Measurement = standard time
This distinction is very important in exams.
5. Basic idea behind method study
Method study is based on one simple question:
“Can this job be done in a better way?”
To answer that, the analyst studies:
- what is being done
- why it is being done
- where it is being done
- when it is being done
- who is doing it
- how it is being done
Then the analyst tries to improve the method.
So method study is basically a questioning and improvement process.
6. Situations where method study is useful
Method study is useful when:
- production cost is high
- workers move too much
- output is low
- layout is poor
- delays happen often
- handling is excessive
- work causes fatigue
- machines stay idle
- bottlenecks exist
- a new process is being introduced
So method study is used both:
- to improve old methods
- to design better new methods
7. Main steps in method study
Method study usually follows a logical sequence.
A common sequence is:
- select
- record
- examine
- develop
- install
- maintain
Let us understand each one.
8. Select
In this step, the job or process to be studied is chosen.
Not every job needs immediate study. Usually, management selects jobs where:
- cost is high
- delays are frequent
- motion is excessive
- complaints are common
- output is low
- safety is poor
So the first step is to identify which job needs improvement most.
9. Record
In this step, all facts about the present method are collected and recorded. Your material notes that the record stage involves gathering sufficient quality and quantity data to act as the basis of evaluation and examination.
This may include:
- sequence of steps
- worker movements
- machine use
- travel distance
- material flow
- time taken
- workplace arrangement
This step is important because no improvement is possible without clear facts.
10. Examine
In this step, each part of the method is examined critically.
Questions asked include:
- why is this step necessary?
- what is being done?
- where should it be done?
- when should it be done?
- who should do it?
- how should it be done?
This is the most analytical step.
It helps identify:
- unnecessary steps
- duplicate work
- bad layout
- avoidable motion
- poor sequence
11. Develop
After examining the existing method, a better method is created.
This improved method may involve:
- removing some steps
- combining operations
- changing sequence
- improving layout
- using better tools
- reducing travel distance
- assigning work more effectively
This is the creative improvement stage.
12. Install
Once the better method is developed, it must be put into actual use.
This may require:
- worker training
- workplace rearrangement
- new instructions
- supervisor support
- trial implementation
A good method has no value unless it is actually adopted.
13. Maintain
After installing the method, the organization must ensure that the improved method continues to be followed.
If supervision is weak, workers may return to the old method.
So this step involves:
- checking compliance
- monitoring results
- making small corrections
- maintaining the new standard
This makes the improvement permanent.
14. Tools used in method study
Method study uses different tools to understand and improve work.
Common tools include:
- process charts
- flow diagrams
- flow process charts
- operation process charts
- two-handed process charts
- string diagrams
These tools help visualize the current method clearly.
Even if you do not go deep into every chart now, remember that method study often uses diagrams and charts to record and analyze work.
15. Process chart
A process chart shows the sequence of operations and inspections involved in a job.
It helps management understand:
- what steps exist
- in what order they occur
- where improvement may be possible
This is useful when studying manufacturing and service procedures.
16. Flow diagram
A flow diagram shows the physical movement of workers, materials, or equipment from one place to another.
It is especially useful when:
- movement is excessive
- layout seems inefficient
- time is lost in travel
A flow diagram can show whether the job path is smooth or wasteful.
17. Principles used in method study
When improving a method, the analyst usually follows some simple principles.
Eliminate
Remove unnecessary work.
Combine
Combine steps when possible.
Rearrange
Change the order of steps for better flow.
Simplify
Make the job easier to do.
These principles help create a more efficient method.
A simple memory line is:
Eliminate, Combine, Rearrange, Simplify
18. Method study and motion economy
Method study is closely related to motion economy.
Motion economy means reducing unnecessary body movement and making useful movements easier.
Examples:
- placing tools near the worker
- reducing bending
- reducing reaching distance
- using both hands effectively
- improving table height
This helps:
- reduce fatigue
- save time
- improve productivity
So method study often leads to better motion economy.
19. Method study and layout improvement
Many method problems happen because the workplace layout is poor.
For example:
- tools may be far away
- materials may move backward
- machines may be badly arranged
- workers may cross paths unnecessarily
Method study can improve layout by:
- reducing travel distance
- improving sequence
- reducing congestion
- improving work flow
So method study and layout are closely connected.
20. Method study and productivity
Method study improves productivity because it reduces wasted effort.
If the same worker can produce more output with the same time and same resources due to a better method, productivity increases.
This happens through:
- less motion
- less delay
- better sequence
- better arrangement
- easier handling
- reduced fatigue
So method study is a direct productivity improvement tool.
21. Advantages of method study
Method study gives many benefits.
Higher productivity
Better methods increase output.
Lower cost
Wasteful steps are removed, so cost reduces.
Less fatigue
Workers do the job with less unnecessary effort.
Better use of machines and materials
Resources are used more effectively.
Better workflow
Movement and sequence become smoother.
Better safety
Hazardous or awkward work methods can be corrected.
Better quality
A clear and systematic method can reduce mistakes and variation.
22. Limitations of method study
Method study is useful, but it also has some limitations.
Worker resistance
Workers may feel change is unnecessary or threatening.
Poor cooperation
If staff and supervisors do not support the study, implementation becomes difficult.
Wrong observation
If the job is not studied properly, the new method may not be effective.
Frequent change in conditions
If design, tools, or volume change often, the method may need repeated revision.
So method study must be practical and well-managed.
23. Conditions for successful method study
For method study to succeed, the organization should ensure:
- management support
- worker cooperation
- proper observation
- accurate recording
- practical improvements
- training after change
- follow-up after installation
Method study should be introduced as a way to improve work, not just to criticize workers.
24. Method study in manufacturing
In manufacturing, method study is used for:
- assembly work
- material handling
- machine loading
- inspection flow
- tool arrangement
- workplace layout
- packing operations
Example:
In a furniture factory, method study may reduce the movement between cutting, drilling, and assembly sections.
25. Method study in service organizations
Method study is not limited to factories.
It can also be used in:
- hospitals
- banks
- offices
- schools
- warehouses
- retail stores
Example:
- reducing patient movement in a hospital
- reducing paperwork steps in a bank
- improving file flow in an office
- improving billing counters in a store
So method study is useful in both manufacturing and services.
26. Difference between method study and time study
This is a very important exam point.
Method study
Method study focuses on how the job should be done.
Time study
Time study focuses on how long the job should take.
So:
- method study improves the method
- time study measures the time
Both are related, but they are not the same.
27. Difference between method study and work study
Work study is the broader concept.
It includes:
- method study
- work measurement
Method study is only one part of work study.
So:
- Work Study = broad
- Method Study = one part
28. Difference between old method and improved method
An old method may involve:
- unnecessary movement
- poor sequence
- wasted time
- more fatigue
- repeated handling
An improved method usually has:
- simpler steps
- better layout
- less movement
- smoother flow
- less effort
- better results
That is why method study is often described as a technique of work simplification.
29. Simple exam-style answer
Method study is the systematic recording and critical examination of the existing and proposed way of doing work in order to develop a more effective and economical method. It is a major part of work study and focuses on finding the best way to do a job. The main steps in method study are select, record, examine, develop, install, and maintain. Method study helps eliminate unnecessary work, reduce movement, improve flow, reduce fatigue, increase productivity, and lower cost. It is useful in both manufacturing and service organizations.
30. Very easy memory version
Method study means:
find the best way to do a job
Remember these steps:
- select
- record
- examine
- develop
- install
- maintain
Remember this improvement rule:
- eliminate
- combine
- rearrange
- simplify
31. Final easy example
Suppose a worker in a warehouse packs parcels.
Before method study:
- the worker walks far to collect items
- labels are kept on another table
- tape is missing often
- boxes are arranged badly
After method study:
- all materials are kept near the worker
- labels and tape are placed together
- the packing sequence is improved
- movement is reduced
Now the worker packs more parcels in less time and with less tiredness.
That improvement in the way of doing the job is called method study.
