Method Study

Test Your Knowledge

Method Study Quiz

Instructions: Choose the best answer for each question.

1. What is the primary goal of method study?

a) To increase the complexity of a task. b) To optimize efficiency and reduce waste. c) To create a standardized work procedure. d) To identify potential safety hazards.

2. Which of the following is NOT a step involved in method study?

a) Define the task. b) Record the existing method. c) Implement and evaluate improvements. d) Develop a budget for the project.

3. How does time study contribute to method study?

a) It identifies the most skilled workers for a task. b) It measures the time required for each step in a process. c) It sets deadlines for completing the analysis. d) It determines the cost of implementing new methods.

4. Which of the following is a potential benefit of method study in oil & gas operations?

a) Increased environmental impact. b) Reduced worker safety. c) Lower production costs. d) Increased reliance on manual labor.

5. Method study is applicable to which of the following areas in oil & gas operations?

a) Only drilling operations. b) Only production facilities. c) Only construction projects. d) All of the above.

Method Study Exercise

Scenario: A drilling crew is experiencing delays in setting up the drilling rig due to inefficient movement of equipment and tools.

Task: Using the principles of method study, propose 3 concrete improvements to optimize the rig setup process.

Consider the following:

• Existing method: The current method involves a chaotic, unorganized approach to moving equipment.
• Potential areas for improvement: Organization of materials, efficient use of personnel, streamlined movement of equipment.

Techniques

Method Study: Optimizing Efficiency in Oil & Gas Operations

This document expands on the core principles of Method Study and its application within the Oil & Gas industry, broken down into specific chapters.

Chapter 1: Techniques

Method study employs several key techniques to analyze and improve work processes. These techniques are often used in combination to achieve comprehensive optimization:

• Process Charting: This involves visually representing the sequence of operations, transportations, inspections, delays, and storages involved in a task. Different types of process charts, such as flow process charts, operation charts, and flow diagrams, are used depending on the complexity and nature of the task. In oil and gas, this could chart the steps involved in well completion or pipeline maintenance.

• Work Measurement: This is the systematic process of determining the time required to perform a task. Techniques such as time study (detailed in the introduction) and predetermined motion time systems (PMTS), like MTM (Methods-Time Measurement) or MOST (Maynard Operation Sequence Technique), are utilized. PMTS allow for estimating times without direct observation, useful for planning new processes. In oil & gas, work measurement can be used to optimize the time taken for rig setup or pipeline inspections.

• Motion Study: This focuses on analyzing the individual movements involved in a task, aiming to eliminate unnecessary movements, reduce fatigue, and improve worker comfort and safety. Techniques include micro-motion study (using film or video recording) and cyclergraph and chronocyclegraph analysis (recording the path and speed of movements). Motion study in oil and gas might improve the efficiency of valve operation or equipment maintenance procedures.

• Workplace Layout Analysis: This examines the physical arrangement of the workplace, including the placement of equipment, materials, and personnel. Techniques such as flow diagrams and process charts are used to identify bottlenecks and improve the flow of work. Optimizing the layout of a drilling rig or a production facility is a prime example in the oil & gas context.

• Ergonomics: This considers the human factors in the design of work, including posture, reach, and force, to minimize the risk of injury and improve worker comfort and productivity. Ergonomic assessments can help to redesign tasks in oil and gas to reduce musculoskeletal injuries related to heavy lifting or repetitive movements.

Chapter 2: Models

While Method Study doesn't rely on specific mathematical models in the same way some statistical process control techniques do, certain models underpin its application:

• Process Mapping Models: These visual representations, like flowcharts and value stream maps, allow for a clear depiction of the current state and potential improvements. Value stream mapping, in particular, helps identify waste (Muda) in the process, a key concept from Lean methodologies often integrated with Method Study.

• Simulation Models: These are used to predict the impact of proposed changes before implementation. Discrete event simulation can model the flow of materials and personnel in a complex system like an oil refinery or a drilling operation. This helps quantify the potential gains from proposed improvements.

• Work Sampling Models: A statistical technique to determine the proportion of time spent on different activities within a task or process. This reduces the need for continuous observation, useful for long-duration processes in oil and gas.

• Linear Programming and Optimization Models: Although less directly applied than the above, these can be used to optimize resource allocation (personnel, equipment) within the context of a Method Study improvement project.

Chapter 3: Software

Several software packages can aid in performing method study:

• Process Mapping Software: Tools like Microsoft Visio, Lucidchart, or specialized process mapping software provide features to create and manage process flowcharts, value stream maps, and other visual representations of processes.

• Time Study Software: Specialized software automates time measurement and data analysis, aiding in performing time studies more efficiently and accurately.

• Simulation Software: Packages like AnyLogic, Arena, or Simio allow for simulating complex processes, testing different scenarios, and predicting the impact of improvements before implementation. This is especially useful for large-scale oil and gas operations.

• Ergonomics Software: Software like RULA (Rapid Upper Limb Assessment) or REBA (Rapid Entire Body Assessment) assists in evaluating ergonomic risk factors in workplace tasks.

• Spreadsheet Software: While not specifically designed for Method Study, programs like Microsoft Excel or Google Sheets are commonly used for data collection, analysis, and reporting.

Chapter 4: Best Practices

Effective implementation of Method Study relies on several best practices:

• Cross-functional team: Include representatives from all relevant departments (operations, engineering, maintenance) to ensure buy-in and a holistic approach.

• Data-driven approach: Rely on objective data (time studies, process charts) to identify and prioritize improvement opportunities.

• Pilot projects: Test new methods on a smaller scale before full-scale implementation to minimize risks.

• Standardization: After improvements are implemented, clearly document the new processes and procedures to ensure consistency.

• Continuous improvement: Implement a system for continuous monitoring and improvement of processes.

• Employee involvement: Engage employees in the process to encourage buy-in and improve the chances of successful implementation. Their experience and insights are invaluable.

• Effective Communication: Regular updates and feedback are crucial for maintaining team morale and ensuring everyone understands the goals and progress.

Chapter 5: Case Studies

(This section would require specific examples. Below are outlines for potential case studies; real-world data would need to be gathered to populate them.)

Case Study 1: Optimizing Well Completion Procedures

• Problem: Excessive time and labor costs associated with well completion operations.
• Methodology: Time study and motion study were employed to analyze the existing process. Process charting identified bottlenecks.
• Results: Significant reduction in well completion time, reduced labor costs, and improved safety.

Case Study 2: Improving Pipeline Maintenance

• Problem: Inefficient inspection and maintenance procedures on a long-distance pipeline.
• Methodology: Work sampling and process charting were used to analyze time spent on different activities and identify inefficiencies. Workplace layout analysis improved access to critical equipment.
• Results: Reduced downtime, improved safety, and lower maintenance costs.

Case Study 3: Enhancing Drilling Rig Setup

• Problem: Lengthy rig setup times leading to project delays and increased costs.
• Methodology: Time study, motion study, and workplace layout analysis were conducted to improve the efficiency of the rig setup process. A simulation model helped to evaluate different scenarios.
• Results: Significant reduction in rig setup time, reduced labor costs, and improved schedule adherence.

These case studies would showcase the practical application of Method Study techniques in various oil and gas operations and highlight the tangible benefits achieved. Each would need detailed data to effectively illustrate the improvements.