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Metallurgical Engineering

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Performance Rating

During the time study, time study engineer carefully observes the performance of the operator. This performance seldom conforms to the exact definition of normal or standard. Therefore, it becomes necessary to apply some 'adjustment' to the mean observed time to arrive at the time that the normal operator would have taken to do that job when working at an average pace. This 'adjustment' is called Performance Rating.

Determination of performance rating is an important step in the work measurement procedure. It is based entirely on the experience, training, and judgment of the work-study engineer. It is the step most subjective and therefore is subject to criticism.

Performance Rating can be defined as the procedure in which the time study engineer compares the performance of operator(s) under observation to the Normal Performance and determines a factor called Rating Factor.

System of Rating

There are several systems of rating the performance of operator on a job.

These are:

• Pace Rating

• Westinghouse System of Rating

• Objective Rating

• Synthetic Rating

A brief description of each rating method follows.

Pace Rating

Under this system, operator's performance is evaluated by considering his rate of accomplishment of the work. The study person measures the effectiveness of the operator against the concept of normal performance and then assigns a percentage to indicate the ratio of the observed performance to normal or standard performance.

In this method, which is also called the speed rating method, the time study person judges the operators speed of movements, i.e. the rate at which he is applying himself, or in other words "how fast" the operator performs the motions involved.

Westinghouse System of Rating

This method considers four factors in evaluating the performance of operator: skill, effort, conditions, and consistency.

Skill may be defined as the proficiency at of an individual in following the given method. It is demonstrated by co-ordination of mind and hands. A person's skill in a given operation increases with his experience on the job, because increased familiarity with work brings speed, smoothness of motions and freedom from hesitations.

The Westinghouse system lists six classes of each factor. For instance the classes of skill are poor, fair, average, good, excellent and super skill. Each class has further two degrees. The time study person evaluates the skill displayed by the operator. And puts it in one of the six classes and also decides the degree in that class, higher or lower, i.e. 1 or 2. As equivalent % value of each class of skill is provided in the Table, the rating is translated into its equivalent percentage value, which ranges from +15 % (for super skill of higher degree) to -22 % (for poor skill of lower degree).

In a similar fashion, the ratings for effort, conditions, and consistency are given using the Table for each of the factors. By algebraically combining the ratings with respect to each of the four factors, the final performance-rating factor is estimated.

Objective Rating

In this system, speed of movements and job difficulty are rated separately and the two estimates are combined into a single value. Rating of speed or pace is done as discussed earlier, and the rating of job difficulty is done by selecting adjustment factors corresponding to characteristics of operation with respect to (i) amount of body used, (ii) foot pedals, (iii) bimanual ness, (iv) eye-hand co-ordination, (v) handling requirements and (vi) weight handled or resistance encountered. Mundel and Danner have given Table of % values (adjustment factors) for the effects of various difficulties in the operation performed.

For an operation under study, a numerical value for each of the six factors is assigned, and the algebraic sum of the numerical values called job difficulty adjustment factor is estimated.

The rating factor R can be expressed as

R = P x D

where; P = Pace rating factor, and

D = Job difficulty adjustment factor.

Synthetic Rating

This method of rating has two main advantages over other methods. These are (i) it does not rely on the judgment of time study person and (ii) it gives consistent results.

The time study is made as usual. Some manually controlled elements of the work cycle are selected. Using a PMT system (Pre-determined motion time system), the times for these selected elements are determined. The times of these elements as determined are compared with the actual observed times and the performance factor is estimated for each of the selected elements.

Performance or Rating Factor, R = P/A

Where P = Predetermined motion time of the element, and

A = Average actual observed time of the element.

The overall rating factor is the mean of rating factors determined for the selected elements. This is applied uniformly to all the manually controlled elements of the work cycle.

Allowances

The readings of any time study are taken over a relatively short period of time. The normal time arrived at, therefore, does not include unavoidable delay and other legitimate lost time, for example, in waiting for materials, tools or equipment; periodic inspection of parts; interruptions due to legitimate personal needs, etc. It is necessary and important that the time study person applies some adjustment, or allowances, to compensate for such losses so that fair time standard is established for the given job.

Allowances are generally applied to total cycle time as some percentage of it, but sometimes these are given separately for machine time as some % and for manual effort time some other %. However, no allowances are given for interruptions which may be due to factors which are within the operator's control or which are avoidable.

Most companies allow the following allowances to their employees.

• Constant allowances (for personal needs and basic fatigue)

• Delay Allowance (for unavoidable delays)

• Fatigue Allowance (for job dependent fatigue)

• Personal Allowance

• Special Allowance

Delay Allowance

This time allowance is given to operator for the numerous unavoidable delays and interruptions that he experiences every day during the course of his work. These interruptions include interruptions from the supervisor, inspector, planners, expediters, fellow workers, production personnel and others. This allowance also covers interruptions due to material irregularities, difficulty in maintaining specifications and tolerances, and interference delays where the operator has to attend to more than one machine.

Fatigue Allowance

This allowance can be divided into two parts: (i) basic fatigue allowance and (ii) variable fatigue allowance. The basic fatigue allowance is given to the operator to compensate for the energy expended for carrying out the work and to alleviate monotony. For an operator who is doing light work while seated, under good working conditions and under normal demands on the sensory or motor system, a 4% of normal time is considered adequate. This can be treated as a constant allowance.

The magnitude of variable fatigue allowance given to the operator depends upon the severity of conditions, which cause extra (more than normal) fatigue to him. As we know, fatigue is not homogeneous. It ranges from strictly physical to purely psychological and includes combinations of the two. On some people it has a marked effect while on others; it has apparently little or no effect. Whatever may be the kind of fatigue-physical or mental, the result is same-it reduces the work output of operator. The major factors that cause more than just the basic fatigue includes severe working conditions, especially with respect to noise, illumination, heat and humidity; the nature of work, especially with respect to posture, muscular exertion and tediousness, and like that.

It is true that in modern industry, heavy manual work, and thus muscular fatigue is reducing day by day but mechanization is promoting other fatigue components like monotony and mental stress. Because fatigue in totality cannot be eliminated, proper allowance has to be given for adverse working conditions and repetitiveness of the work.

Personal Allowance

This is allowed to compensate for the time spent by worker in meeting the physical needs, for instance a periodic break in the production routine. The amount of personal time required by operator varies with the individual more than with the kind of work, though it is seen that workers need more personal time when the work is heavy and done under unfavourable conditions.

The amount of this allowance can be determined by making all-day time study or work sampling. Mostly, a 5 % allowance for personal time (nearly 24 minutes in 8 hours) is considered appropriate.

Special Allowances

These allowances are given under certain special circumstances. Some of these allowances and the conditions under which they are given are:

Policy Allowance: Some companies, as a policy, give an allowance to provide a satisfactory level of earnings for a specified level of performance under exceptional circumstance. This may be allowed to new employees, handicap employees, workers on night shift, etc. The value of the allowance is typically decided by management.

Small Lot Allowance: This allowance is given when the actual production period is too short to allow the worker to come out of the initial learning period. When an operator completes several small-lot jobs on different setups during the day, an allowance as high as 15 percent may be given to allow the operator to make normal earnings.

Training Allowance: This allowance is provided when work is done by trainee to allow him to make reasonable earnings. It may be a sliding allowance, which progressively decreases to zero over certain length of time. If the effect of learning on the job is known, the rate of decrease of the training allowance can be set accordingly.

Rework Allowance: This allowance is provided on certain operation when it is known that some percent of parts made are spoiled due to factors beyond the operator's control. The time in which these spoiled parts may be reworked is converted into allowance.