Monday, October 20, 2025

Machine Work Study - Online Book - Narayana Rao



Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign

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Machine Work Study – Industrial Engineering Analysis of Machine in Production System - A Presentation 



Machine Work Study – Man Work Study – Taylor’s Conceptualization of Scientific Study of Man-Machine Systems is a presentation done by Dr. K.V.S.S. Narayana Rao, Professor,  (NITIE), in December 2015

Taylor (1911) “The Principles of Scientific Management”  - Scientific management in a machine shop. 

Taylor described the implementation of scientific management in a machine shop.

First Stage – Machine Related Improvements

The slide-rules developed for determining optimal speeds and feeds were used to determine the optimal speed and feed for every element of work done on this machine.

The Pulling power of the machine at its various speeds and feeds was determined.

The belt drive and pulleys of the machine were adjusted so that the machine can be run at the proper speed for each element.

The shape of tools was specified and the tools made of high-speed steel (already in use in the company) were properly dressed, treated, and ground.

After preparing the machine, tools and instruction cards in this way, the machinist was asked to work according to the new instruction card and all varieties of work were finished on the lathe and the times were recorded.
The gain in time was found to range from two and one-half times to nine times.


Handwork of Operators – Time and Motion Study

The change from rule-of-thumb management to scientific management involves, however, not only a study of machine effort, that is the proper speed for doing the work and a remodelling of the tools and the implements in the shop, but also study of human effort.

Hence elaborate analysis of the hand work was done.

Hand work depends upon the manual dexterity and speed of a workman, independent of the work done by the machine. On some machines, the time saved by scientific hand work was greater than that saved in machine-work.


Industrial Engineering Discipline - Neglected Machine Productivity Improvement

Industrial Engineering discipline has not developed a subject for analysis of machine related elements and over time the area got neglected. Facilities planning and Material Handling were included in IE programmes but they were also not integrated adequately with process improvement (productivity engineering) function adequately.

Early Authors on Scientific Management.

They recognized the machine work improvement.

Bertrand Thompson  (wrote between 1914 to 1920)

Scientific management was implemented -  first, by determining with the aid of experienced investigators the best materials, equipment, machine methods and man methods to use. In many machine shops, it was the practice to issue to the workman an instruction card containing directions as to feeds, speeds, tools, and times of machine elements and also the manual elements with their standard times in their proper sequence. The combination of machine work improvement and man work improvement resulted in substantial improvements in machine shop work

Malcolm Keir (1918)

Scientific management advocates development of science and a thorough investigation of the work involving analysis of materials, equipment, environment; motion study, fatigue study, time study; research into the laws of health, psychological experiment and community improvement.

Farquhar (1919)

Difference between improving impersonal means of production and human effort in production.


In his paper, he took up for description first, the mechanical phase - the more purely impersonal aspects - divorced so far as possible from the human factor.  He stated that the two were to a certain extent interactive, yet sufficiently distinct to warrant separate treatment.

H.B. Maynard (1927 & 1937)

H.B. Maynard, a popular industrial engineer of the next generation, was a coauthor of "Time and Motion Study and Formulas for Wage Incentives" Stewart McKinley Lowry, Harold Bright Maynard, Gustave James Stegemerten, McGraw-Hill Book Company, Incorporated, 1927. In that book "operation analysis" was described. It evaluated various aspects of the production system including the machine. Maynard and Stegemerten later   authored "Operation Analysis" in which they discussed each and every step of operation analysis in a separate chapter. This book should have been included in IE curriculums.

One Conclusion

There is a need for developing a subject of machine element and work analysis in IE curriculum based on the definition. "Industrial engineering is system efficiency engineering and human effort engineering" by Narayana Rao.

Machine Work Study - Lessons

Study of machine work has to begin with production engineering lessons related to the machine in use. In this series of lessons of machine tool work is covered.

Metal Cutting Theory - Productivity Focus Lessons


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Metal Cutting Processes - Industrial Engineering and Productivity Aspects
https://nraoiekc.blogspot.com/2020/07/metal-cutting-processes-industrial.html

News - Information for Maintenance Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-maintenance.html

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Machine Tools - Industrial Engineering and Productivity Aspects

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Machining Cutting Tools - Industrial Engineering and Productivity Aspects

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Machine Tool Toolholders - Industrial Engineering and Productivity Aspects

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Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects

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Machining Process Simulation - Industrial Engineering and Productivity Analysis

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Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects

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Surface Finish - Industrial Engineering and Productivity Aspects

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Work Material - Machinability - Industrial Engineering and Productivity Aspects

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Machine Rigidity - Industrial Engineering and Productivity Aspects

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Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations

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Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects


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High Speed Machining - Industrial Engineering and Productivity Aspects

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Design for Machining - Industrial Engineering and Productivity Aspects



Process Planning of Machining




Process Analysis for Productivity Improvement Opportunities




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Productivity Engineering


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Machine Work Study - Machine Time Estimation - Machine Time Reduction - Machining Cycle Time Optimization


Now the machine shop process industrial engineering that includes all focus areas of industrial engineering is developed.


Metal Cutting Theory -  Developments - News


Metal Cutting Theory, Machines and Tools for Machine Work Study


Metal cutting theory is the basis for machine work study or machining process industrial engineering. Understanding process planning is the next step in the knowledge base. Process planning provides step by step instructions to carry out a given job for machining. The process plan is the input for industrial engineering study.

Machine work study and other areas of industrial engineering applied in machining process is explained in:

Machine Shop Process Industrial Engineering



Cutting Tools


Industrial Engineering - Hand Tools, Cutting Tools and Machine Accessories for Productivity


Jigs and Fixtures


Jigs and Fixtures - Principles, Books, Manuals

Setup Time Reduction (SMED)


Eight Steps or Principles for SMED - Shigeo Shingo

CNC Machine - Setup Time Reduction - Bibliography - Case Studies

Poka - Yoke


Poka-Yoke - Shigeo Shingo

Special Purpose Machines


Special Purpose Machines for Increased Productivity

Smart Machines


Productivity Improvement Through Smart Machines

Many articles need to be added to this book


Updated on 20.10.2025, 9 May 2020,  26 March 2020
9 May 2019
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