Industrial Engineering and Ergonomics

Industrial Engineering and Ergonomics
Unit 5
Modeling and optimizing manual work processes with MTM
Fall Winter 2016/2017
Dr.-Ing. Dr. rer. medic. Dipl.-Inform. Alexander Mertens

Univ.-Prof. Dr.-Ing. Dipl.-Wirt.-Ing. Christopher M. Schlick
Chair and Institute of Industrial Engineering and Ergonomics
RWTH Aachen University
Bergdriesch 27
52062 Aachen
phone: 0241 80 99 494
email: m.mertens@iaw.rwth-aachen.de
© Chair and Institute of Industrial Engineering and Ergonomics, RWTH Aachen University
Learning Targets
 Learning the basic principles of the sequence-analytical time

modeling (predetermined motion-time systems) of manual work
processes
 Getting to know and generally being able to independently apply

MTM (“Methods-Time Measurement”)
 Being acquainted with compressed MTM data systems
 Being capable of choosing the correct MTM data system in

practice
 Being acquainted with the possibilities and limitations in the

usage of MTM
© Chair and Institute of Industrial Engineering and Ergonomics, RWTH Aachen University 5-2
Introduction: Automobile assembly
How to conduct “line-

balancing” of manual tasks in
an assembly line, so that the
utilisation is as high as
possible without constraining
the employees by the process
design?
Source: DPA; Spiegel Online 2008
Clock cycle
Work station 1 W 1.1

Material flow
W 1.2
W 1.3
Illustration for line- Work station 2 W 2.1.1

balancing
W 2.1.2
(Gantt chart) W 2.2
W 2.3
Work station 3 ...
Methods for the determination of time data
Determining time
experimental methods computational methods

(ACTUAL TIMES) (TARGET TIMES)
observation self-report comparison and compilation calculation of

estimation work cycles
• manual time • made by the worker • Comparison of the • systems of
measurement
– list of activities, work procedures for predetermined times • based on
- stopwatch which the time - Methods Time process
their duration, and
- video analysis standards are to be Measurements models (e.g.,
the frequency of
- REFA procedures determined with (MTM) for turning)
their occurrence
• work sampling similar activities for - Work Factor (WF)
(time measurement
(e.g., office work) • with quantitative
which time standards
by means of information
• with the aid of have already been
statistical analysis) • standard times processing
devices (e.g., set.
- catalogue of models
– frequencies computer log-files)
• The estimation is task times • with
(MMH)
based on standard - nomograph biomechanical
– time-on-task
(MMZ) times for the proce- models
dure based on
• interview historical records or
techniques experience
(comparative
estimation).
Statistical time models Sequence-analytical time models
MTM as a Predetermined Motion-Time System
Methods The method
Time determines the
Measurement time
 MTM is a predetermined motion-time system (PMTS).
 Predetermined motion-time systems are methods to fractionalize manual

operational procedures, which can be influenced by the worker, in elements of
motions and to assign motion time standards to these elements.
Motion element 1 2 3 4 5
Right hand motion 1 2 3 4 5
Left hand motion 1 2 3 4 5
time
Application of Predetermined Motion-Time Systems
(PMTS)
PMTS applications
design of the work

time determination work instruction
system
• planning of the • creation of target • description of the

operating process times operating processes
• optimization of the • determination of for education and
operating process standard time for instruction materials
• design of tools and performance-related
equipment wages
• design of the • pre-costing
manufacture
Historic milestones in the development of PMTS
1900
F. W. Taylor: Scientific Management
(fractionalization of tasks and measurement of subtracted
times)
1910
F. B. Gilbreth (1911) Motion Study
(Gilbreth detected that human motions can be put down to
seventeen fundamental motions - Therbligs - by dint of film
1920 shots.)
R. Thun (1925)
(proposals for the development of a system of
1930 pre-determined times)
WF (Work Factor): Start of development (1934)
1940 MTM: Start of development (1940)

WF published in 1945 (Quick et al.)
MTM published in 1948
1950 (H. B. Maynard, J. L. Schwab, G. J. Stegemerten)
1970
MOST published in 1972 (K. Zandin)
Development of MTM-1 - Procedure
Acquisition of motion sequences and their influencing variables

in different work situations with different workers by means of
film shots
(single pictures with a rate of 16 pictures per second)
Determination of actual times by counting single pictures
Compensation of interpersonal performance variation by using

the Lowry-Maynard-Stegemerten (LMS) method
Compensation of variance by regression analysis

 Result: MTM-1 metric card
Development of MTM-1 -
The Lowry-Maynard-Stegemerten method
actual time according median LMS-

to video analysis /  performance index of =
MTM standard
performance
time recording the evaluation group
A standard performance of 100% is described within the LMS method as

“performance of a moderately high trained person who can show this
performance in perpetuity without work fatigue”.
LMS: Lowry, Maynard, Stegemerten
(names of the developers of this
performance index
method) according to LMS
influences dependent influences independent

from people from people
constancy of working
dexterity effort conditions
execution time
(e.g. lightning)
Development of MTM-1 -
Results
Result of the development:

MTM-1 metric card
The MTM-1 metric card

comprises time values for
fundamental motions subject to
time-influencing factors
Time values are stated as TMU

(Time Measurement Unit)
1/100,000 h = 1 TMU
0.036 s = 1 TMU
Deutsche MTM-
Vereinigung e.V.
© Chair and Institute of Industrial Engineering and Ergonomics, RWTH Aachen University 5 - 10
MTM-1:
Fundamental motions at a glance (1a)
5 fundamental motions of the finger-, hand-, and arm-system
Release Reach
Motion
cycle Grasp
Position
Move
Deutsche MTM-
Vereinigung e.V.
MTM-1:
Fundamental motions at a glance (1b)
Comparison of the learning progress for the different motions:
 The performance of time per

person A
motion
simple motions such as person B
person C
Reach and Move can
hardly be improved by
Grasp Position
means of additional
training.
 Difficult motions such
as Grasp and Position
are available for training
and can thereby be Reach Move
improved.
training time training time
(Source: Rohmert & Kirchner, 1969)
MTM-1:
Fundamental motions at a glance (2)
3 additional fundamental motions of the

finger-, hand-, and arm-system:
Apply Pressure
Disengage
Resistance which is
to be overcome to
Turn open the fridge’s
door
Deutsche MTM-
Vereinigung e.V.
MTM-1:
2 fundamental motions of the eyes:
Eye travel
D = 30 cm
T = 40 cm
Eye focus Deutsche MTM-

Vereinigung e.V.
MTM-1:
15 fundamental motions for body movements:

body
movements
without shift of with shift of with inclination

body axis body axis of body axis
 bend
 arise from bend
 side step  stoop
 foot motion  arise from stoop
 turn body
 leg motion  kneel on one knee
 walk  arise from kneel on one knee
 kneel on both knees
 arise from kneel on both
knees
 sit
 stand
MTM-1: Time-influencing factors considering
reaching as example
“Reach” (R) is the fundamental movement
1. Distance moved
for moving the fingers or hand to a determined or
Messpunkt
Bewegungslänge in cm
undetermined location.
Messpunkt
Distanc Time TMU
e moved R-C mR-A mR-B m-Wert Case and Description
R-A R-B R-E
in cm R-D R-Am R-Bm für B
2. Case of motion 2 or less

4
2,0
3,4
2,0
3,4
2,0
5,1
2,0
3,2
1,6
3,0
1,6
2,4
0,4
1,0 A Reach to object in fixed location,
6 4,5 4,5 6,5 4,4 3,9 3,1 1,4 or to object in other hand or on
which other hand rests.
8 5,5 5,5 7,5 5,5 4,6 3,7 1,8
10 6,1 6,3 8,4 6,8 4,9 4,3 2,0
12 6,4 7,4 9,1 7,3 5,2 4,8 2,6
14 6,8 8,2 9,7 7,8 5,5 5,4 2,8 B Reach to single object in location
16 7,1 8,8 10,3 8,2 5,8 5,9 2,9 which may vary slightly from cycle to
cycle.
18 7,5 9,4 10,8 8,7 6,1 6,5 2,9
20 7,8 10,0 11,4 9,2 6,5 7,1 2,9
Pictured example: R-B 22 8,1 10,5 11,9 9,7 6,8 7,7 2,8
24 8,5 11,1 12,5 10,2 7,1 8,2 2,9 C Reach to object jumbled with
26 8,8 11,7 13,0 10,7 7,4 8,8 2,9 other objects in a group so that
3. Type of 28 9,2 12,2 13,6 11,2 7,7 9,4 2,8
search and select occur.
30 9,5 12,8 14,1 11,7 8,0 9,9 2,9

motion path 35 10,4 14,2 15,5 12,9 8,8 11,4 2,8
40 11,3 15,6 16,8 14,1 9,6 12,8 2,8 D Reach to a very small object or
45 12,1 17,0 18,2 15,3 10,4 14,2 2,8 where accurate grasp is required.
v 50 13,0 18,4 19,6 16,5 11,2 15,7 2,7

55 13,9 19,8 20,9 17,8 12,0 17,1 2,7
Typ I
60 14,7 21,2 22,3 19,0 12,8 18,5 2,7
t 65 15,6 22,6 23,6 20,2 13,5 19,9 2,7
E Reach to indefinite location to get
hand in position for body balance or
R30B 70 16,5 24,1 25,0 21,4 14,3 21,4 2,7 next motion or out of way.
v v 75 17,3 25,5 26,4 22,6 15,1 22,8 2,7
80 18,2 26,9 27,7 23,9 15,9 24,2 2,7
Typ II t t
R30Bm mR30B
grasping as example
Time-influencing “Grasp” (G) is the fundamental motion which is

factors: accomplished to keep one or several items in check
with fingers or hand, so that the following fundamental
1. Mode of
motion can be carried out.
grasping
Case TMU Description
2. Position of item G1A 2,0 Pick Up Grasp: Small, medium or large object by itself, easily grasped.
3. Constitution of G1B 3,5 Very small object or object lying close against a flat surface.
item G1C1 7,3 > 12 mm Ø

Interference with grasp on bottom and one side of nearly
G1C2 8,7 6 to 12 mm Ø
cylindrical object.
G1C3 10,8 < 6 mm Ø
G2 5,6 Regrasp. Shift of the control point of an item without losing control of item
G3 5,6 Transfer Grasp. One hand takes over control of an item while other releases.
G4A 7,3 > 25x25x25 mm

Select grasp:
G4B 9,1 6x6x3 bis 25x25x25 mm Object jumbled with other objects so search
and select occur.
G4C 12,9 < 6x6x3 mm
Contact, sliding or hook grasp. Gain sufficient control over item through
G5 0,0
contact so that following fundamental movements can be executed.
grasping as example
G1A G1B G1C
Pick up grasp G 1
Highly frequent in Frequent in practice Seldom in practice
practice
Regrasp G 2
Start of motion Motion End of motion
Transfer grasp G 3
Right hand (dashed) to Right hand (dashed)
Handing over has taken on check on
left hand
the item.
G4A G4B G4C
Two partial dimensions should fall in the respective category.

Select grasp G 4 > 25 x 25 x 25 mm
> 6 x 6 x 3 mm
< 6 x 6 x 3 mm
< 25 x 25 x 25 mm
7,3 TMU 9,1 TMU 12,9 TMU
Application of MTM-1:
Procedure
Motion analysis
Segmentation of the motion sequence in
elements, i.e. reaching.
Time analysis
Determination of the time-influencing factors for
every single motion element, i.e. distance moved,
or property of item.
Coding
of the motion element and of the influencing
variables.
Extraction
of the elementary motion time from the charts.
Addition
of the elementary motion times to obtain the basic
motion time in demand.
Example
Description of the Necessary information for the Coding Time Value
motion sequence time allocation
Reach • Distance moved: 40 cm R 40 C 16,8 TMU

for bolt • bolt is mixed with others
Grasp • admeasurements:  8 x 12 mm G4B 9,1 TMU

at bolt • bolt is mixed with others
Move • Distance moved: 40 cm

M 40 C 18,5 TMU
the bolt to • accuracy of placing: move object
apparatus to exact
location
Position • assembling tolerance: tight P2SE 16,2 TMU

the bolt • symmetry: fully symmetric
to hole • handling: easy
Release • opening the fingers RL 1 2,0 TMU

of bolt
Cumulative time 62,6 TMU 

needed 2,25 s
Systematics of the Motion Sequence (1)
Motion sequence
successive movements non-successive movements
Successive movements are single

movements or movements in a
series which are executed
simultaneous combined
consecutively by the same or
movements movements
different body parts without
temporal overlapping and
interruption.
Description A H Code TMU Code A H Description

12.8 R30B pens
2.0 G1A
15.1 M30C device
5.6 P1SE
2.0 RL1
Motion sequence
simultaneous combined
movements movements
TMU Code A H Description

Combined movements are two
9.1 G4B
or more completed
10.5 (M16C device
movements that are executed
(G2
at the same time by one body
5.6 P1SE
part.
In the example, a non time-determinig re-grasping (with the same hand)

occurs during the movement.
Motion sequence
Simultaneous movements are single simultaneous combined

movements or movements in a series movements movements
that are executed by different body parts
at the same time.
Left hand Right hand
Description A H Code TMU Code A H Description
pens R20C 11.4 [R10C pens
9.1 G4B
G4B 9.1
device M16C) 10.5 (M16C device
G2) (G2
P1SE 5.6 P1SE
RL1 2.0 RL1
Read-off example for the simultaneity of movements:
Determining criteria for Disengage Position Grasp Move Reach

the simultaneity of
movements:
 Degree of control of
Reach
basic movements
 Degree of practice of the Move
worker
 State of the site/ the Grasp
objects
Position
Disengage
Possibilities for within normal field of view

simultaneous execution:
outside normal field of
view
easy
with practice Easy to handle
difficult Difficult to handle
V5-1
Bimanual movements
Example of application: Assembly of two bolts –
Analysis using MTM-1
Reach R30C 14,1 TMU

Grasp G4B 9,1 TMU
Move M30C 15,1 TMU
Position P2SE 16,2 TMU
Release RL1 2,0 TMU
Reach R30C 14,1 TMU
Grasp G4B 9,1 TMU
Move M30C 15,1 TMU
Position P2SE 16,2 TMU
Release RL1 2,0 TMU
Total Time 113 TMU
left hand right hand

R30C 14,1 TMU R30C
G4B 9,1 TMU
9,1 TMU G4B
M30C 15,1 TMU M30C
16,2 TMU P2SE
P2SE 16,2 TMU
RL1 2,0 TMU RL1
81,8 TMU
Possibilities and limitations in the application
of MTM-1
Application of MTM-1
 mass production in large batches
 limited product variety
 short-cyclical workflows
 exactly defined basic conditions
 experienced, highly trained employees
 workstations with a detailed-oriented design
evaluation creation
comparison comparison
process of short- of the
of of design
optimization cyclical work plan
processes alternatives
workflows and training
Further development of MTM (1)
objectives of
change of the requirements for
further
market analysis systems
development
shortening of the high analysis

product-life-cycles accommodation to the
speed
method level in the following
areas of application:
increase in the
sufficient
number of single-part and
accuracy of
alternatives small-series production
the time data
smaller batch sizes

series production
transparency and
frequently-changing reproducibility
production requests of the time data
MTM for single-part and Universal Analyzing

small- series production System
(MEK)
work process
values of production area
sequence of operation MEK - UAS -
data compression
stages of stages of
steps of operation
extension extension
fundamental operation MEK UAS
sequence of motions basic values
fundamental motion MTM-1
single-part/ series production mass production

small-series
low method level high
Deutsche MTM-
Vereinigung e.V.
sequence of fundamental
fundamental motions
motions operations
MTM standard data / MTM-UAS/

MTM-1
basic values -MEK
Reach
Grasp Get
Move Get and Place
Position Place
Data construction by high and transverse

Release
aggregation
Deutsche MTM-
Vereinigung e.V.
Application Example: Comparision of MTM-1 and
MTM-UAS at a soldering process
MTM-1 MTM-UAS
Left hand Right hand
Description Code TMU
Description Code TMU Code
Reach R30B 12,8 [R35A Get and Place AC2 55
Grasp G1A 2,0 G1A
Move M30C 15,1 Handle the soldering
HC2 70
Move 16,8 M35C iron
Position P2SE 16,2 Soldering PT 100
Position 43,0 P3SE
Release PA2 20
Soldering PT 100,0
Move M30B] 16,8 M35C Total 245
Position 5,6 P1SE
Release RL1 2,0 RL1
Gesamt 230,3
Application example:
Carburetor of type Stromberg 175 CD-2
Comparison of MTM-1 and MTM-UAS using the example of

learning process of the subassembly of a carburetor
T [s] T [s]
industrial mechanic, T1 = 603
graphical work plan
T5 = 291
TUAS = 146 TUAS = 146
0 250 500 750 1000 1 2 3 4 5

n n
MTM-1 MTM-UAS
Predicted assembly time 140s 146s
Number of MTM components 975 182
Advantages and disadvantages of the MTM
methodology
Advantages
 It is possible to determine operating processes and execution times explicitly
already in the planning phase of a work system.
 Training periods can be reduced since employees can already be trained before
the introduction of new work processes.
 It is possible to design work systems in a target-oriented way, as influencing
variables concerning the execution times become transparent by means of the
MTM methodology.
 MTM time values are based on a 100% standard performance. An evaluation of
the performance rate – as to be found in REFA Stop watch time study – is not
necessary.
 The coding of the motion elements leads to an internationally homogenous,
reproducible description of the operational procedures.
Disadvantages
 The implementation of MTM is limited to manually operated tasks. V5-2
Final example
 The analysis effort is rather high.
 The analysis can be influenced subjectively.
Quick Knowledge Check
 What is the purpose of predetermined motion-time systems?
 What was the procedure during the development of MTM-1?
 Which 5 fundamental motions of the finger-, hand-, and arm-system

can be distinguished within MTM-1?
 What is the procedure for the application of the MTM method?
 What are the preconditions for the application of MTM-1?
 What are the reasons for the development of compressed

MTM methods?
 How do you determine which MTM analyzing system should

be applied in operational practice?
 What are the advantages and disadvantages of the MTM method?
References
 Antis, W.; Honeycutt, J.M.; Koch, E.N. (1973): The Basic Motions of MTM, The Maynard Foundation, fourth
edition.
 Bokranz, R.; Landau, K. (2006): Produktivitätsmanagement von Arbeitssystemen – MTM-Handbuch, Schäffer-
Poeschel Verlag Stuttgart.
 Gilbreth, F.B. (1911): Motion Study: A Method for Increasing the Efficiency of the Workman, Van Nostrand, New
York.
 Jeske, T.; Schlick, C. (2012): A New Method for Forecasting the Learning Time of Sensorimotor Tasks. In:
Advances in Ergonomics in Manufacturing, S. 241-250, Boca Raton (FL).
 Maynard, H.B.; Stegemerten, G.J.; Schwab, J.L. (1948): Methods-time Measurement. McGraw-Hill Book
Compony, New York.
 Rohmert, W.; Kirchner, J.H. (1969): Anlernung sensumotorischer Fertigkeiten in der Industrie. Beuth, Berlin.
 Salvendy, G. (2001): Handbook of Industrial Engineering, Wiley-Interscience, New York, N. Y. 10158, third
edition.
 Schlick, C.; Bruder, R.; Luczak, H. (2010): Arbeitswissenschaft, Springerverlag Berlin Heidelberg.

Industrial Engineering and Ergonomics

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Industrial Engineering and Ergonomics

Uploaded by

Copyright:

Available Formats

Industrial Engineering and Ergonomics

Dr.-Ing. Dr. rer. medic. Dipl.-Inform. Alexander Mertens

 Learning the basic principles of the sequence-analytical time

 Getting to know and generally being able to independently apply

 Being acquainted with compressed MTM data systems

 Being capable of choosing the correct MTM data system in

 Being acquainted with the possibilities and limitations in the

How to conduct “line-

Work station 1 W 1.1

Illustration for line- Work station 2 W 2.1.1

Work station 3 ...

experimental methods computational methods

observation self-report comparison and compilation calculation of

Statistical time models Sequence-analytical time models

Methods The method

Time determines the

 MTM is a predetermined motion-time system (PMTS).

 Predetermined motion-time systems are methods to fractionalize manual

Right hand motion 1 2 3 4 5

Left hand motion 1 2 3 4 5

design of the work

• planning of the • creation of target • description of the

WF (Work Factor): Start of development (1934)

1940 MTM: Start of development (1940)

Acquisition of motion sequences and their influencing variables

Determination of actual times by counting single pictures

Compensation of interpersonal performance variation by using

Compensation of variance by regression analysis

actual time according median LMS-

A standard performance of 100% is described within the LMS method as

influences dependent influences independent

Result of the development:

The MTM-1 metric card

Time values are stated as TMU

5 fundamental motions of the finger-, hand-, and arm-system

Comparison of the learning progress for the different motions:

 The performance of time per

training time training time

(Source: Rohmert & Kirchner, 1969)

3 additional fundamental motions of the

2 fundamental motions of the eyes:

Eye focus Deutsche MTM-

15 fundamental motions for body movements:

without shift of with shift of with inclination

2. Case of motion 2 or less

30 9,5 12,8 14,1 11,7 8,0 9,9 2,9

v 50 13,0 18,4 19,6 16,5 11,2 15,7 2,7

Time-influencing “Grasp” (G) is the fundamental motion which is

item G1C1 7,3 > 12 mm Ø

G4A 7,3 > 25x25x25 mm

G4A G4B G4C

Two partial dimensions should fall in the respective category.

Reach • Distance moved: 40 cm R 40 C 16,8 TMU

Grasp • admeasurements:  8 x 12 mm G4B 9,1 TMU

Move • Distance moved: 40 cm

Position • assembling tolerance: tight P2SE 16,2 TMU

Release • opening the fingers RL 1 2,0 TMU

Cumulative time 62,6 TMU 

successive movements non-successive movements

Successive movements are single

Description A H Code TMU Code A H Description

successive movements non-successive movements

TMU Code A H Description