Work system design | EveryEng

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Work system design

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930 min

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Mechanics & Turbomachinery

Mechanical Engineering

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Why enroll

Participants join this course to learn how to design and improve work systems that balance productivity, efficiency, safety, and human well-being. The course equips learners with practical and analytical tools to study work methods, measure performance, and develop optimized workflows that reduce waste, fatigue, and operational inefficiencies.

The program is especially valuable for students and professionals interested in industrial engineering, production management, ergonomics, and operations. Participants gain the ability to analyze real-world work environments, apply ergonomic principles, and design jobs and workplaces that enhance both employee comfort and organizational performance.

By joining this course, learners strengthen their problem-solving and decision-making skills and gain industry-relevant knowledge applicable to manufacturing and service sectors. The course also provides a strong foundation for advanced studies and professional roles in productivity improvement, lean systems, and human-centered system design.

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Engineering Academy

Engineer

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5+ yrs experience·India

Is this course for you?

You should take this if

You work in Mechanics & Turbomachinery
You're a Mechanical Engineering / Production Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Mechanical Engineering
You need live interaction with an instructor

Course details

Work System Design is a fundamental course in industrial and production engineering that focuses on the systematic design, analysis, and improvement of work systems to achieve high productivity, efficiency, safety, and worker well-being. The course integrates principles of ergonomics, work study, human factors, and operations management to develop optimized methods for performing tasks in manufacturing and service environments.

The course begins with an introduction to work systems and their components, including workers, machines, materials, methods, and the working environment. It emphasizes the importance of understanding human capabilities and limitations in designing effective work systems. Concepts such as anthropometry, biomechanics, physiological factors, and workplace ergonomics are covered to ensure safe, comfortable, and efficient job design.

Key topics include method study, work measurement, time study, standard time determination, and productivity analysis. Students learn to analyze existing work methods, eliminate unnecessary motions, and develop improved processes using tools such as process charts, motion study, and principles of motion economy. The course also addresses job design, work layout planning, and material handling systems to enhance workflow and reduce fatigue and delays.

In addition, Work System Design covers workplace safety, environmental factors, and quality of work life, highlighting their impact on employee performance and organizational effectiveness. Modern approaches such as lean manufacturing, work system optimization, and the use of digital tools for work analysis are introduced to align the course with current industrial practices.

By the end of the course, learners gain the skills required to design and evaluate efficient, safe, and human-centered work systems. The knowledge acquired is highly relevant for careers in manufacturing, operations management, ergonomics, industrial engineering, and productivity improvement initiatives.

source : NPTEL [youtube]

Course suitable for

Key topics covered

introduction to work system design
flow process charts
operation process charts
human aspects of work study
case study on productivity
productivity measures

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

29 lectures15 hr 30 min

Work System Design
5 min
Work System Design: Introduction
30 min
Work Study: Basic Concept
31 min
Techniques of Work Study
38 min
Flow Process Charts
36 min
Flow Process Charts: Examples
32 min
Two-Handed-Process Charts
36 min
Multiple Activity Charts
34 min
Operation Process Charts: Examples
34 min
Operation Process Charts
35 min
Method Study: Recording Techniques
39 min
Method Study: Steps
33 min
Method Study: Basic Concept
38 min
Human Aspects of Work Study
36 min
Concept of Work Content
34 min
Steps Involved in Work Study
34 min
Case Study on Productivity
35 min
Numerical Problems on Productivity
28 min
Productivity Improvement Technique
35 min
Causes of Low Productivity
31 min
Factors Influencing Productivity
25 min
Productivity Measurement Models
28 min
Productivity Measures
26 min
Measurement of Productivity
35 min
Introduction and Concept of Productivity
33 min
Development and Selection of New Method
31 min
Critical Examination Techniques
38 min
Installation and Maintenance of Improved Methods
30 min
Memo-Motion Study
30 min

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Questions and Answers

Q: You're leading a pre-startup review and searching "ASME B31.3 hydrotest requirement temporary piping during commissioning" because a punch list item was conditionally cleared. The temporary spool is still installed, drawings are Rev 4, and as-built is unknown. What drives the decision on whether startup without re-testing is acceptable?

A: The boundary definition is the tripwire here. B31.3 allows pressure testing by system, not by intent, and anything outside the documented test boundary is untreated risk. Visual condition or assumed shop tests don't close that gap. From a Lean startup view, restarting a test is wasteful, but running with an unverified boundary invites rework or worse.

Q: You're pulling GA and P&ID and googling "pump seal flush plan drawing mismatch during startup". Rev 4 drawings show API Plan 11, but the instrument list calls out Plan 32 with external flush. Field piping exists but isn't tagged. What's the cleanest next step before startup?

A: Plan 32 lives or dies on flush quality and pressure margin. That's the threshold. Assuming Plan 11 or editing drawings doesn't change what's physically installed. Verifying the external flush conditions is fast, reduces startup churn, and aligns with first-pass yield thinking.

Q: You're checking materials and searching "carbon steel corrosion wet H2S startup standby". The turbomachinery lube oil cooler sees intermittent wet H2S during idle periods. Which degradation mechanism sets the inspection priority?

A: Wet H2S at low temperature pushes you into cracking risk, not wall loss. The hardness and stress threshold is what matters. Uniform corrosion and sulfidation sit in different operating windows, and chasing them burns inspection effort without payoff.

Q: During hot circulation you're searching "compressor surge margin drops when suction temperature increases". Suction temperature rises 10°C above design while speed stays fixed. What happens first, and what's the right response?

A: That 10°C bump shifts the map. Reduced density cuts developed head, pulling you closer to surge. Opening recycle feels counterproductive to throughput, but it's the move that protects the machine and avoids a longer outage.