The Principles of Motion

Economy

Motions @ Work
The Principles of Motion Economy

 The effectiveness of a motion pattern is

determined by

“The Principles of Motion Economy”.

The Principles of Motion Economy

 The most important of these are :

Use of the Human Body

The Workplace

Design of Tools and Equipment

The Principles of Motion Economy

 Finally, remember the big picture. All

methods improvements have a cost, but
some cost far more than others

 Think of methods improvements as

Big Methods Little Methods

It’s free!!!!!
The Principles of Motion Economy

 The highest productivity is achieved

when we:

 Reduce the Number of motions

 Reduce the distances moved
 Reduce precision
 Reduce eye-shifts
The Principles of Motion Economy

 Simplify grasps
 Toss dispose rather than place dispose
 Make the best use of both hands
encourage rhythm
 Promote natural posture and
movement
Fundamental
questions ??? about
sewing operation
Fundamental questions about sewing
operation :

 Is this operation necessary?

 Should this operation or portions of the

operation be combined with another
operation?
 Is the operation performed in the correct
sequence?
 What sewing machine attachments or work-
aids are needed?
 Will the operation yield satisfactory levels of
quality?
Fundamental questions about sewing
operation :

 What type of training curve will the job yield?

 What material usage factors are affected by

the job?

 What principles related to the usage of the

human body should be taken into account?

 What considerations on space and indirect

labour requirement (helper) apply?
Methods Checklist

Get Yes No
1. Disposal of previous operation leave parts in best
position for “get”
2. Parts located as close to the needle as possible
3. Grasp of parts from the original bundle easiest
4. Parts got without looking
5. Parts got during sewing period

Prepare for needle or insert in folder

1. Assemble parts or fold directly in front of needle (No
re-position)
2. Insert part in folder with a single push
Methods Checklist

Sew Yes No
1. Retain original alignment of parts while sewing
2. Resume sewing after start without pause
3. Quick turns while sewing
4. Continuous & full speed sewing
5. Needle stops in correct position
Dispose
1. Dispose by throwing
2. Dispose without looking
Motions
1. Simplest motion pattern is used
2. Principles of motion economy are being enforced
Methods Engineering

 This topic involves methods engineering at the

individual workplace. It is important to note that
methods engineering is greatly influenced by the
basic sewing room design.

 The use of a transporter for example can

sometimes limit workplace refinement. For this
reason, it is necessary to plan methods and
sewing room design simultaneously so that the
correct trade-offs between effective individual
operation methods and the realities of the
business objectives are chosen.
Methods Engineering

 Machinery selection must, of course, be related

to methods engineering. Also, methods
standardisation is an absolute requirement for
accurate work measurement which will be
discussed in the next section.

Note: For purposes of this discussion we shall assume

the sewing room design is correct and that we have
selected the best machine for each individual
operation in the sewing room.
Fundamental Questions and
Techniques

 Before considering specific methods for a job,

a series of fundamental questions should be
asked about the operation.

 Once these fundamental questions have been

resolved, detailed methods engineering can
begin. In this regard, there are several basic
industrial engineering tools which are often
helpful.
 Process Charting

 For methods analysis, charting techniques are

available. Multiple activity charts (Gang Process)
are used where a crew of operators work on the
same operation or assembly line. Man-machine
charts are used to analyse the operator’s activity
in relation to the machine. Micro-motion studies
and charting on a Micro-Motion Study Simo Chart
is another approach. For the typical sewing
operation, the use of a simple left hand - right
hand activity chart describing the motions of
each hand and the time value is often adequate.
In short, it is usually helpful to make a detailed
examination of the existing motion path utilised
and process charting forces one to do this.
Process Chart Symbols
Recording of the facts is greatly facilitated by use of standard symbols.
These together represent all types of activities.

- OPERATION :
It indicates the main steps in a process, method or procedure.

- INSPECTION :
It indicates an inspection for quality or check for quantity.

- TRANSPORT :
It indicates the movement of workers, materials or equipment
from place to place.

- DELAY :
It indicates delay in the sequence of events e.g. Waiting.

- PERMANENT STORAGE :
It indicates a controlled storage having Receipt / Issue record.
 FLOW PROCESS CHART / Material Type
Flow Process Chart Activity Present Proposed Saving
Subject : Garment Handling 7
7
Activity : Finishing the Garment 2
3
Charted By : 0
Distance

Sr .# DESCRIPTION REMARKS
1 Garments in stitching
2 Transport to Finishing Section
3 Perform Clipping
4 Clipping Inspection
5 Send to Press
6 Pressing
7 Final Inspection
8 Super Inspection
9 Send Garments to Packing
10 Folding Garment
11 Forward to next
12 Apply Clips
13 Forward to Next Operation
14 Apply UPC
15 Forward to next
16 Pack in Poly – Bag
17 Forward to next
18 Paste Sticker on Poly Bag
19 Store in Pigeon Holes.

Total :
7 7 2 3 0
 Operation Chart or Process Chart

EXAMPLE :
Crew Neck T- Shirt SAMs
Label Rib

0.22
Label Cutting 0.06 Rib Cutting 0.08 Close Sleeve (O/L)

Label Inspection 0.30

Inspection Blind Hem Sleeve (O/L)

O/L Shoulder 0.23

Attach Rib to Neck 0.32

Attach Label to Neck 0.19

Trim Neck Thread 0.10

Top Stitch Shoulder & Neck 0.29

O/L Arm hole 0.54

Blind Hem Bottom (O/L) 0.26

Inspection
Man-Machine Chart

 Uses:
 Graphical productivity techniques to improve
Man-Machine Utilization

 To record simultaneous activities of a work

system of one or more workers.

 Purpose:
To show the most productive way to use multiple operators,
machine, or any combination of people and machines
Activity Chart
Man-Machine Chart

Process Description:

 One operator is work perform the following

activities on a semi-automatic washing machine :

 Load
 Unload
 Idle when machine is run mode
Man-Machine Chart
 One operator – One machine
Man-Machine Chart
Man-Machine Chart One-Man – One Machine

 Analysis :

 Process time = 14 min.

 Operator utilization = 43%

(6/14*100)

 Idle time = 8 min.

 Machine utilization = 100%

Man-Machine Chart One-Man – Two Machine

 Analysis :

 Process cycle = 18 min.

 Operator utilization = 86%

(12/14*100)

 Idle time = 4 min.

 Machine utlization = 78%

Man-Machine Chart One-Man–Three Machine

 Analysis :

 Process cycle = 14 min.

 Operator utilization = 100%

(14/14*100)

 Idle time = 0 min.

 Machine utlization = 100%

Man-Machine Chart
 Summary :

No. Machines Cycle time Time/Unit

or Load
1 14 14 min.
2 18 7 min.
3 14 6 Min
Man-Machine Chart

 Conclusion:

 Operator is kept busy 100 % of the time with 3

machines

 The savings time per unit must be compared

against the cost of additional machine

 The cost of additional machine is also

influenced by the amount of wash available.
 Simo Chart

 This is similar to “Two-hand Chart” with the

difference that the time required for each motion is
drawn to scale with the vertical axis and
sometimes coloured to represent the particular
motion.

 Procedure :
 A camera with high speed clock is placed under the work
place area and is used to film time and the operators
actions simultaneously. After recording, film is worked
and processed and viewed to determine the motions
performed and time taken. From these records, activities
and time taken are plotted in the form of Simo Chart.
Simo Chart
Operation: Assembly nut and
Sketch Code
bolt
X= bolt Method = Improved
Y=nuts Operator = XYZ
Z=chairs Department = Assembly
L=finish units Time units = 0.001 Min.
M=assembly area Prepared by = XYZ

LH Motions Time Time Scale Time RH Motions

Reach to x 15 10 15 Reach to y
Grasp bolt 4 20 4 Grasp nut
Return to z 10 30 10 Return to z
Position bolt 21 50 21 Position nut
Hold 15 70 15 Assemble
Carry to L 15 80 15 Idle
Released 4 100 4 Idle
Gantt Chart
 A Gantt chart is a simple graphical representation showing
the time needed for all project activities, as well as the
earliest times when activities can begin.
Month 0 2 4 6 8 10
Activities

E
 Slack
F
is the amount of
time an activity can
be delayed without
Duration of Duration of
delaying the project. Slack
Activity Critical Activity
Right and Left Hand Activity Chart
Principles of Motion Economy

 Once we have formally analysed the basic

motions involved, it is possible to apply the laws
of Motion Economy. These rules have been
researched extensively by Professor Ralph M.
Barnes of the University of California. Since
approximately 80% of typical operation time in
sewing involves handling to and from the
machine, it is critical that the basic motions used
are sound.

 An application of principles 1 and 3 would be the

pick up of a pocket and facing one with each
hand simultaneously.
General Classification of Hand Motions

 One important principle of motion economy

relates to the classification of hand motions.
These are categorised as follows:
 Finger motions.
 Motions involving fingers and wrist.
 Motions involving fingers, wrist and forearm.
 Motions involving fingers, wrist, forearm and
upper arm.
 Motions involving fingers, wrist, forearm,
upper arm and shoulder.
General Classification of Hand Motions

 The law states the lowest classification is

usually preferred since it requires the least
amount of time and effort, and produces
less fatigue.

 An example of the use of this principle

involves picking up of a front from
overhead shelf. This effectively reduces
motion class to (3) versus class (5).
 Precision

 Another technique is
to reduce precision
in the required
finger motions by
use of such devices
as edge guides and
label dispensers as
well as sewing
tolerances of the
stitch line.
Kinesthetic Sense

 A final fundamental technique involves

Kinesthetic Sense. it is generally true that a
person can reach to a location on his body
much more effectively than to some inanimate
object away from his body.

 An example is touching the end of your nose

versus the tip of your tie. Because of this, it
is often helpful to position garment parts in
the operators lap for pick-up or dispose.
Another example would be a shoulder pick-up.
The Method Study ‘7 step’ procedure

1 Select The work to be studied

2 Define Objectives

3 Record Relevant information and data

4 Examine Relevant information and data

5 Develop The improved method

6 Install The improved method

7 Maintain The improved method

Some specific sewing room methods
approaches

 Table cut-offs or extensions.

 Raising of machine.

 Special work aids (air jets, ticket holders, etc.).

 Chutes between selected operations (mobile

carts).

 Special pick-up shelves or boxes.

Some specific sewing room methods
approaches

 Table cut-outs.

 Close location of parts to needle.

 Disposal configuration and next operation.

 Pick up and position without re-grasping.

 Folding or matching of parts en route to machine.

Some specific sewing room methods
approaches

 Both hands involved in simultaneous motions.

 Threads broken during sewing or other elements.

 Use of foot or knee operated devices.

 Clamping of work for waterfall dispose.

Work – Aids
Work – Aids
Work - Aids
Principles of motion economy as related
to the use of the human body

These rules are the most important in sewing

room as handling to and from the machine
comprises 80% of sewing room work.

1. The two hands should begin as well as complete

their motions at the same time.

2. The two hands should not be idle at the same

time except during the rest periods.
Principles of motion economy as related
to the use of the human body

3. Motions of the arms should be made in

opposite and symmetrical directions and should
be made simultaneously;

Examples :

a. Pick up pocket and facing, one with each hand,

simultaneously.
b. Pick up side tabs and elastic and place elastic on
tabs
Principles of motion economy as related
to the use of the human body

4 . Hand motions should be confined to the lowest

classification with which it is possible to perform
the work satisfactorily. This means use motions
requiring only fingers and wrist if a motion of the
forearm and shoulder can be avoided;

Example:
Position parts to be picked up as near to the
operator as possible. Use raised boxes for storage
of parts if this will help to get the work nearer.
Principles of motion economy as related
to the use of the human body

5 . Momentum should be employed to assist the

worker wherever possible

6. Smooth, continuous motions of the hands are

preferable to zigzag motions or straight-fine
motions involving sudden and sharp changes in
direction

e.g., The use of an automatic chain-cutting presser foot and a

gravity disposal in sewing on a facing to a pocket enables the
disposal to be made with the same motion of the hand as
guides it through the needle.
Principles of motion economy as related
to the use of the human body
7. Built up movements are faster, easier and more
accurate than restricted or "controlled"
movement.

8. Rhythm is essential to the smooth and automatic

performance of an operation and the work should
be arranged to permit an easy and natural
rhythm wherever possible;
Example:
Using a presser foot knife and a rear disposal rail on a side
seaming or serging operation enables the operator to pull back the
chain over the knife and throw the end of the trouser leg over the
rail in a smooth motion following a long sewing seam. The use of
clamps for holding one end of long pieces when working on the
other end provides the same sort of conditions
Principles of motion economy as related
to the use of the Work Place

1. There should be a definite and fixed place for all tools

and materials.

2. Tools, materials and controls should be located close in

and directly in front of the operator. Boxes for parts as
in the elastic and tabs example, label holders on the
machine head and turning attachments between
machine head and the operator on the edge of the table
are examples. Tables to the left of the needle are often
best cut away to allow trucks to be moved as near as
possible to the needle.

3. Gravity feed bins and containers should be used to

deliver material close to the point of use.
Principles of motion economy as related
to the use of the Work Place

4. "Drop deliveries" should be used wherever possible;

Example:

Gravity feed bins for pieces such as hooks and eyes,

zipper slides, buttons, etc.

5. Materials and tools should be located to permit the best

sequence of motions, for

Example:

Right angled layout of tandem presses with disposal rail

between them and pick-up opposite the disposal with
room for operator to turn and move in a straight line
between the two.
Principles of motion economy as related
to the use of the Work Place

6. Provision should be made for adequate conditions for

seeing. Good illumination is the first requirement for
satisfactory visual perception. This is a specialist
subject on its own but good fluorescent general
lighting and needle lights are commonly accepted
practice in sewing rooms.

7. The height of the workplace and the chair should be

arranged so that alternate sitting and standing at work
is easily possible. This is not generally possible on
sewing operations but inspection tables and other
manual operations can be set at the correct height (1"
to 3" below elbow for alternate sitting and standing).
Principles of motion economy as related
to the use of the Work Place

8. A chair of the type and height to permit

good posture should be provided for every
operator;

Example:

a. All seats should be adjustable to suit different

heights..
Principles of motion economy as related
to the use of the Tools and Equipments

1.The hands should be relieved of all work that can be

done more advantageously by a jig, a fixture, or a
foot operated device

Example:

a. Foot pedal operated clamps on tackers

b. Foot operated controls on a needle positioner.
c. Knee operated needle positioner.
d. Foot pedal operated pocket turning attachment which
pushes a blade into the comer of the pocket
Principles of motion economy as related
to the use of the Tools and Equipments

2. Two or more tools should be combined wherever

possible

Example:
a. Attachments already mentioned which perform two operations
at once .

3. Tools and materials should be pre-positioned

whenever possible;

Example:
a. Suspension of hand iron over buck.
 Principles of motion economy as related
to the use of the Tools and Equipments

4. Where each finger performs some specific movement, such as

in typewriting, the load should be distributed in accordance
with the capacities of the fingers;

Example :

a. The forefinger is the strongest and finger controls such

as steam controls on irons and solenoid actuators are
best positioned so that they are in fact operated by the
forefinger.
Principles of motion economy as related
to the use of the Tools and Equipments

5. Handles such as used on cranks and large screwdrivers

should be designed to permit as much of the surface of the
hand to come into contact with the handle as possible. This
principle is of minor importance in sewing room work.

6. Levers, crossbars and hand wheels should be located in such

a position that the operator can manipulate them with the least
change in body position and with the greatest mechanical
advantage. This principle applies particularly to the design of
machines and one can think of many controls which do not
obey this rule, such as reverse levers. Incidentally, there are
now available foot and elbow operated reverse levers which
show that the principle is in fact being applied as machine
design improves.
Principles of motion economy as related
to the use of the Tools and Equipments

5. Handles such as used on cranks and large screwdrivers

should be designed to permit as much of the surface of the
hand to come into contact with the handle as possible. This
principle is of minor importance in sewing room work.

6. Levers, crossbars and hand wheels should be located in such

a position that the operator can manipulate them with the least
change in body position and with the greatest mechanical
advantage. This principle applies particularly to the design of
machines and one can think of many controls which do not
obey this rule, such as reverse levers. Incidentally, there are
now available foot and elbow operated reverse levers which
show that the principle is in fact being applied as machine
design improves.
WORK PLACE AREA

Maximum
Work Place Area

Minimum
Work Place Area
Assembly operation for Repetitive
Work

4 4
3 3
2 2
1 1

Left Hand Right

Hand
Can any operation be made easier?

By a better tool?
By changing position of control or tools?

By using better material, containers, racks, bins or

trucks?

By lessening visual requirements?

By using inertia where possible and

avoiding it where work must overcome
it?

By better workplace heights?

Take the Work out of Work

Don’t take it easy

Make it easy!
Thanks