Organizational Efficiency depends upon Improvement in

Productivity

Quality

Cost

Delivery

Safety, Health & Environment

Morale

What is Productivity

Mahindra Production

No of Vehicles

Productivity =

Output

Or Deliverable

Input

Manpower Or
Resource
consumed

For fix or constant Output, to Improve Productivity

What is in Our hand is to reduce Input
How it can be Done?

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Deployment of Manpower is done on the basis of

Work content

Work content is defined by using

Work Measurement
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Work Measurement

Mahindra Production

What Is a Work measurement?

A work measurement is a specification for
performing a unit of work (operation).
A work measurement addresses:
How an operation should be
performed (method)
How long an operation
should take (time)

Measurement

Method

Time

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Uses of Work Measurement

Determine labor costs
Plan and schedule workers and machines
Determine feasibility of producing a new product
Plan overall production schedule
Set production goals
Review achievement of goals
Gauge individual or departmental efficiency
Determine the actual costs of production
Mahindra Production

Work Measurement Systems History

1 Time Study : F W Taylor 1900s
2 Motion Study: Gilbreth

1920s

3 PMTS (Predetermined Motion

Time Systems):
> MTM I (Methods Time
Measurement)

1940s

> Work Factors

1950s

> MTM II

1950s

> MOST (Maynard Operation

Sequence Technique)1970s
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What Is Time Study?

Time Study is a work measurement technique that:
Uses a stopwatch to time operations
Adjusts the time by applying a
performance rating that reflects
performance of an average worker

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Average Trained Worker

A representative average of those employees
who are trained and able to satisfactorily perform
any and all phases of the work involved, in
accordance with the requirements of the job
under consideration.

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Average Trained Worker

Works with average skill and effort
Is not a super-performer, not an under-achiever
Is sufficiently trained

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Normal Pace
Consistent, continuous pace
Pace that can be maintained throughout the work
period without causing undue fatigue

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Performance Rating
The analyst observes the worker to determine if
he/she is performing the work at an average
level.
If the worker is performing at an above average level,
the performance rating increases the time.
If the worker is performing at a below average level,
the performance rating decreases the time.
105%

90%

95%

Mahindra Production

What is a Predetermined Motion Time

System (PMTS)?
A work measurement technique that utilizes
catalogs (tables) of standard times which are
assigned to fundamental motions that make up
an activity.
The times for the fundamental
motions are totaled to determine
the normal time for performing
the activity.
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Features of PMTS
Eliminates the need for subjective performance
ratings
Allows for simulation/forecasting
Facilitates methods improvement

105%

90%

95%

Mahindra Production

The History of PMTS

Pioneered by the micro motion studies of Frank
and Lillian Gilbreth
Manual activities are combinations of basic elements.
Reduced motion = reduced time = higher productivity

Numerous work measurement

systems followed.

TI M

PR

E&

ITY
V
TI MOT
C
IO
U
N
OD

Mahindra Production

Methods Time Measurement (MTM)

Developed by H. B. Maynard, in 1948
Based on micro motions established by the
Gilbreths
Identifies the variables which affect the time to
perform each motion

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Basic Elements

Reach

Leg - Foot Motion

Move

Side Step

Turn

Turn Body

Apply Pressure

Walk

Grasp

Bend

Position

Release

Disengage

Eye Travel

Eye Focus

Stoop
Kneel on One Knee
Kneel on Both Knees
Sit and Stand from a Sitting
Position

Mahindra Production

Maynard Operation Sequence Technique

(MOST)

Considered a revolutionary PMTS

Developed by Kjell Zandin and H. B. Maynard and

Company, Inc. in 1974

Based on MTM:
The movement of objects follows consistently repeating
patterns.
Repeated patterns in the sequence of MTM have been
consolidated.

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Features of MOST
Reduces application time
Is accurate
Is easy to learn and use
Requires a minimum of paperwork
Generates consistent results
Encourages method improvement
Can be used in a wide variety of industries
100% performance level
activity timings can be obtained in advance

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MOST Work Measurement Systems

BasicMOST
The most commonly used version of MOST
Typically used for :
Activities that are medium cycle (a few seconds to
approximately 10 minutes)
Repetitive and non-repetitive activities

AdminMOST
Version of BasicMOST that focuses on analyzing administrative
and clerical activities

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MOST Work Measurement Systems

MiniMOST
Produces a very detailed and precise analysis
Typically used for activities that:
Are short cycle (approximately 20 seconds or less)
Are highly repetitive; occur frequently
Feature very little variation

MaxiMOST
Typically used for setups, heavy assembly, maintenance or utilities
Longer cycle activities (2 minutes to more than several hours)
Activities that are non-repetitive or vary widely from cycle to cycle
variations

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MOST Analysis Components

MOST Analysis
Method Description

Sequence Model
Phases
Parameters (A, B, G)
Index Values
(1, 3, 6)
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Method Description
Documents the action performed
Clear, concise and easily understood
Comprised of recommended words

Example:
Pick up a marker that is three steps away on the floor
and lay the marker aside on the flip chart.
Method Description: Move 3 steps, bend & arise,
grasp marker from floor, Move 3 steps, put on flip
chart
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Sequence Models
Sequence models represent the sequence of
events that occurs when an object is moved or a
tool is used.
Predefined sequence models represent different
types of activities.
General Move (moved freely through space)
Controlled Move (movement restricted; attached
or in contact)
Tool Use (using common hand tools)
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MOST Analysis

Example:
Pick up a marker that is three steps away on the floor and lay the
marker aside on the flip chart.

Get
A6 B6 G1
Return
How did I GET the object?

How did I PUT the object?

RETURN?

Put

A 6B0 P 1

A0

A6 = Walk three to four steps to object

B6 = Bend and arise
G1 = Gain control of one light object
A6 = Move object three to four steps
B0 = No body motion
P1 = Put object aside
A0 = No return necessary

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Time Calculation

Get
A6 B6 G1

Put
A6 B0 P1

Return
A0

To arrive at the time for the step:

Sum the index values.
6 + 6 + 1 + 6 + 0 + 1 + 0 = 20

Multiply by a factor of 10 to get time value (in

BasicMOST).
20 x 10 = 200 TMU
Mahindra Production

Time Measurement Units

1 TMU = 0.00001 hour

1 hour = 100,000 TMU

1 TMU = 0.0006 minutes

1 minute = 1667 TMU

1 TMU = 0.036 seconds

1 second = 27.8 TMU

Mahindra Production

MOST

Maynard
Operations
Sequence
Technique

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A MOST analysis is a complete study of an

operation consisting of one or several method
steps and corresponding sequence models,as
well as appropriate parameter time values and
total normal time for the operation. MOST
concentrates on the movements of objects

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Concept of MOST
In Work, you move an object
GET and PUT
For example, you can lift a box and place it
down three feet away.
This is the foundation of BasicMOST and the
sequence models that make up MOST.

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Sequence Models
There are three types of sequence models:
General Move

ABG ABP A

Controlled Move

ABG MXI A

Tool Use

ABG ABP _ ABP A

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MOST Analysis
Break down the task in method steps
Each method step involves the movement of an object:
Freely Through Space

GENERAL MOVE

Over a Restricted Path

CONTROLLED MOVE

Using a Tool

TOOL USE

Apply the appropriate time values to each parameter in

the sequence model.
Total the time for the sub-operation

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General Move

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General Move
Spatial displacement of an object. The object
follows an unrestricted path through the air.
Examples of General Moves
Grasp an object and put it on a shelf.
While holding a part, walk to a bin and
drop part in.
Take a washer from your pocket and
put it on a bolt.
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General Move Phases

Get

Put

Return

ABG

ABP

Parameters
A = Action Distance
B = Body Motion
G = Gain Control
P = Placement
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Data Card

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Action Distance
A0 - Any displacement of the fingers, hands, and/or feet, either
loaded or unloaded. Eg. Reaching between the keys on a pocket
calculator or placing nuts,washers on bolts located <2apart.

A1- Well defined workstation, all parts & tools can be reached
without displacing the body by taking step.

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A3- The trunk of the body is shifted or displaced by walking,

stepping to the side, or turning the body around using one or two
steps. Steps refer to the total number of times each foot hits the
floor.
(One step = 0.75 meter or 2 & feet)

The last parameter used to allocate time for an operator to return

by walking to his or her workplace (starting position) Time for
returning hand without steps is normally not allowed on the last A
parameter, since moving hands to another object or objects is a
part of the initial A parameter of the subsequent sequence model.

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Body Motion (B)

Refers to either vertical (up and down) motions of the
body or the actions necessary to overcome an obstruction
or impairment to body movement.

B3 - bend and arise, 50% Occurrence. And Sit or stand

without moving chair.

B6 - Bend and Arise From an erect standing position, the

trunk of the body is lowered by bending from the waist and/or
knees to allow
the hands to reach below the knees and
subsequently return to an upright position. Bending from waist
with the knees stiff, stooping down by bending at the knees, or
kneeling down on one knee.
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B10 - Sit or Stand, When the act of sitting down or standing up

requires a series several hand, foot, and body motions to move
a chair or stool into a position that allows the body either
Sit or Stand

B16

Stand and bend , Bend and Sit ,Climb On or Off

Mahindra Production

Gain Control (G)

Gain Control covers all manual motions(mainly finger, hand, and foot
employed to obtain complete manual control of an object and
subsequently to relinquish that control.

Light Object- GRASP Any type of grasp can be used as long as no

difficulty is encountered. Pick up hammer from work bench, Obtain

one washer from a parts bin full of washers.Grasp lever, crank, knob
toggle switch, foot pedal. Light objects Simo, Picking Hammer and nail,
pick up a pencil and a straight-edge, using both the hands.

Light Object(s) Non Simo.- GET Because of the nature of job or

the conditions under which the job is performed, the operator is unable
to gain control of two objects or of two suitable grasping points of one
object simultaneously.While one hand is grasping an object, the other
hand must wait before it can grasp the other object.
Mahindra Production

G Heavy or Bulky - GET

3

Control of heavy or bulky objects is achieved only after the

muscles are tensed to a point at which the effects of the difficulty
created by the weight, shape, or size are overcome.The hesitation or
pause needed
for the attainment of sufficient muscular force
required to move the object.Eg Get hold of automobile battery
located on the floor. Take hold of a loaded hand cart before pulling.
Get hold of briefcase by reaching over other baggage. Pickup empty
television packing box.

G3 Blind or Obstructed- GET,FREE

The operator must

feel around for the object before it can be grasped. The fingers or
hand must be worked around the
obstacle before reaching the
object.

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G3

DISENGAGE is characterized by the application of pressure (to

overcome resistance) followed by the sudden movement and recoil of
the object. The recoil of the object must follow an unrestricted path
through air. Eg. Disengage tightly fitting socket from a ratchet tool.
Remove knife stuck in wood. Disengage the cork from a wine bottle.

G3 Interlocked
The object is intermingled or tangled with other objects and must
be separated or worked free before complete control is achieved. Eg.
Remove hammer from crowded toolbox. From a box of springs, gain
control of one spring that is tangled with another.

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G3:COLLECT
Gaining control of several objects is accomplished. The
objects may be jumbled together in a pile or spread over a
surface.
COLLECT WILL COVER gaining control of up to two objects
( two grasps) per hand I.e. a total of four if two hands are
used simultaneously. E.g.. Grasp handful of nails from a bin.
Collect several sheets of paper lying on the table. Get
handful of change from your pocket.

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Placement (P)
Placement refers to actions occurring at the final stage of an objects
displacement to align, orient or engage the object with another before
control of the object is relinquished. Placement includes limited amount
of insertion( up to 2, 5 cm.) as a part of placement.

Pickup object(s) PICKUP, CARRY. HOLD.

Placement does not occur. The object is picked up and held.

PICKUP should be used within reach and CARRY for a pickup
followed by steps.

Toss object(s)-TOSS, THROW,

The objects released during preceding move (action distance

parameter) without placing motions or pause to point the object
toward the target. Eg. Toss a finished part into a bin.Throw balled- up
paper into a trash can.

Lay Aside - MOVE

The object is placed in an approximate location with apparent

aligning or adjusting motions. This placement requires low control by
mental, visual or muscular senses.
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P1 Loose Fit
The object is placed in more specific location, but tolerances are
such that only modest amount of mental a,visual, or muscular
control is necessary to place it.The clearance between engaging
parts is loose enough so that a single adjusting motion, without
application of pressure, is required to seat or position the object.
Eg. Place washer on bolt. Put coat hanger on rack. Place dull pencil
into a sharpener.

P3 Adjustments PLACE,REPLACE
Adjustments are defined as the corrective actions occurring at the
point of placement caused by difficulty in handling the object,
closeness to fit uncomfortable working conditions.
Eg. Place key in lock. Align center punch to scribe a mark.

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P3 Light Pressure
Due to close tolerances or the nature of placement, application of force
is needed to seat the object . e.g. Place moist stamp on a envelope
Insert electric plug into a socket.

P3 Double Placements
Two distinct placements occur during the total placing activity.
e.g. to assemble two parts held by fixture. Place an original on a
photocopy machine

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Parameter Indexing
Get

Put

Return

A1B 0G 3

A1B 0P1

A0

Follow sequence model and look up index values according to application rules
Sum the index values
1+0+3+1+0+1+0=6

Multiply by 10
6 X 10 = 60 TMU

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Examples 1. Grasp a bolt & washer simultaneously from different bins, put
washer on bolt.
2. Get hand tray from 2-3 steps & return to keep it in vehicle.
3. Get the cap of marker from table& Put the cap on the marker
with light pressure
4. Pick up a large box within reach and stack it neatly in place
on a pallet 2 steps away
5. Take a spring from bin & fit it on assembly which is below
knee.
6. After removal of plastic cover from subassembly, move 3
steps to dust bin, throw it and return to workplace.
Mahindra Production

Frequencies
Get

Put

Return

ABG

ABP

One or more of the parameters in the General Move

Sequence can occur more than once.

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Examples - Frequencies

Get

Put

Return

ABG

ABP

Pick up a book and put it within reach on a shelf. (repeat action for a
second book)

(A1B0G1

A1B0P1

A0) 2

Collect 4 pins from a bin and put them individually into 4 loose fitting
slots (distances are within reach)

A1B0G3

(A1B0P1)

A0 (4)

Mahindra Production

Examples - Frequencies

Get

Put

Return

ABG

ABP

Collect a handful of washers from a bin within reach and put on six bolts
located 5 inches apart.

A1B0G3

(A1B0P1)

A0

(6)

1+ 0 + 3 + ((1+0+1) X 6 )+ 0 = 16
16 X 10 = 160 TMU

Mahindra Production

Controlled Move

Mahindra Production

Controlled Move
The movement of objects along a controlled or
restricted path
Examples of Controlled Moves:
Push a button.
Pull a lever 8 inches.
Flip a switch.
Press a clutch pedal.

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Controlled Move Phases

Get

Move/Actuate

Return

ABG

MXI

Parameters

A =
B =
G =
M = Move Controlled
X = Process Time
I = Alignment
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Data Card

Mahindra Production

M Move Controlled
Push/Pull/Pivot

M0 No Action

M1 Push/Pull/Pivot < 12 inches (30 cm.)

Push Button
Push or Pull Switch
Rotate Knob

Mahindra Production

M Move Controlled
Push/Pull/Pivot

M3 Push/Pull/Pivot > 12 inches (30cm.)

Push/Pull with Resistance
Seat
Unseat
Push/Pull with High Control
Push/Pull with 2 Stages < 12 in. (30cm.) each
Push/Pull with 2 Stages < 24 in. Total

Mahindra Production

M Move Controlled
Push/Pull/Pivot
M6

Push/Pull with 2 Stages > 12 in. (30cm.)

Push/Pull with 2 Stages > 24 in. Total
Push with 1 - 2 Steps

M10 Push/Pull 3 - 4 Stages

Push/Pull with 3-5 Steps

M16 Push with 6 - 9 Steps

Mahindra Production

M Move Controlled
Crank
Cranking actions are performed by moving the
fingers, hand, wrist, and/or forearm in a circular
path more than half a revolution.
M3

1 Revolution

M6

3 Revolutions

M10

6 Revolutions

M16

11 Revolutions

M24

16 Revolutions
Mahindra Production

M Move Controlled
Push-Pull Cranking

Back and forth movement of the elbow instead of pivoting at the wrist
and/or elbow.

This type of cranking is analyzed by using the number of pushes plus

pulls as a frequency for the M1 parameter. (M3 if there is substantial
resistance). Where possible, push-pull cranking should be replaced
with pivotal cranking.

Mahindra Production

X Process Time
The portion of work controlled by electronic or
mechanical devices or machines, not by manual
actions.
Used for machine controlled activities having a
fixed, short duration.

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X Process Time
X0

No Process Time

X1

.5 Sec.,

X3

1.5 Sec., .02 min., .0004 hr.

X6

2.5 sec., .04 min., .0007 hr.

X10

4.5 sec., .07 min., .0012 hr.

.01 min., .0001 hr.

Note: Values are read up to and including.

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I Alignment

Manual actions following the Move Controlled or at the conclusion of

process time to achieve an alignment or specific orientation of objects

Eye Times are considered in the Alignment process.

Area of normal vision requires no additional eye time
Circle 4 inch (10cm) in diameter at 16 inches (40cm) distance
If one of the two points lies outside the area of normal vision,
two separate alignments are required.

Three Categories
Alignment of Typical Objects
Alignment of Machine Tools
Alignment of Non-Typical Objects
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Alignment

Typical Objects
I0

No Alignment

I1

Align to 1 Point

I3

Align to 2 Points < 4 in. (10cm.)

I6

Align to 2 Points > 4 in. (10cm.)

I16

Align with Precision

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Alignment

Machining Tools

I3

Align to Workpiece

I6

Align to Scale Mark

I10

Align Indicator Dial

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Alignment

Non-typical Objects (Flat, Large Flimsy, Sharp, Difficult to

Handle)

I0

Against Stop(s)

I3

1 Adjustment to Stop

I6

2 Adjustments to Stop(s)
1 Adjustment to 2 Stops

I10

3 Adjustments to Stop(s)
2-3 Adjustments to Linemark

Mahindra Production

Index the Sequence Model

1. A press operator grasps the handle of a safety gate within
reach and pulls it open 15 inches.
2. A punch press operator pushes two buttons simultaneously
within reach to actuate the press. Press cycles for 2.5
seconds.
3. Reach 2 grasping points on a box (non simo and within
reach)and push the box along a conveyor walking 4 steps.
4. Operator moves to trolley which 6 steps away & rotate trolley
for other side of trolley to in front, with 8 steps.
5. An operator gains control of a section of glass within reach
and carefully slides into a fixture
Mahindra Production

Tool Use

Mahindra Production

Tool Use
Combination of General Moves and Controlled
Moves
Covers the handling and use of tools
Get Tool
Put Tool
Tool Action
Aside Tool
Return
Mahindra Production

Tool Use
Examples of Tool Use activities:
Secure a cap on a bottle with 5 finger spins.
Fasten a screw with a screwdriver 8 wrist turns.
Loosen a nut with a wrench using 3 wrist strokes.
Cut open a box with a knife.
Read 3 words from purchase order.
Wipe a surface with a cloth.

Mahindra Production

Tool Use Phases

Get
Tool

Put
Tool

A B G

A B P

Tool Use
Parameters

Tool
Action
F
L
C
S
M
R
T

Aside
Tool

Return

A B P

Fasten
Loosen
Cut
Surface Treat
Measure
Record
Think
Mahindra Production

Tool Use Analysis

Get
Tool

Put
Tool

Tool
Action

A B G

A B P

Aside
Tool

Return

A B P

Pick up a screwdriver from the table within reach

and place it on the head of a screw, turn down
the screw 9 wrist turns and set aside the tool.
A1B0G1

A1B0P3

F16 A1B0P1 A0 = 240 TMU

Mahindra Production

Fasten / Loosen & Tool Placement

Mahindra Production

Cut, Surface Treat, Measure, Record and Think

Mahindra Production

F/L Fasten or Loosen

Includes manually or mechanically assembling or
disassembling one object to or from another using
the fingers, hand or a hand tool
Finger Actions
Wrist Actions
Arm Actions

Mahindra Production

Index the Sequence Model

Get
Tool

Put
Tool

A B G

A B P

Tool
Action

Aside
Tool

Return

A B P

Obtain a nut from a parts bin located within

reach, place it on a bolt and fasten with
12 finger actions.
A1 B0 G1

A1 B0 P3

F16

A0 B0 P0 A0 = 220 TMU

Mahindra Production

C Cut
Manual actions employed to separate, divide or
remove part of an object using a sharp-edged
hand tool
Pliers
Scissors
Knife

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S - Surface Treat
Activities aimed at cleaning material or particles
from or applying a substance, coating or finish to
the surface of an object
Air-clean
Brush-clean
Wipe

Mahindra Production

M Measure
Actions employed to determine a certain physical
characteristic of an object by comparison with a
standard measuring device

Identify Measurement Device

Profile Gauge

Steel Tape

Fixed Scale

Depth Micrometer

Caliper

OD-Micrometer

Feeler Gauge

ID-Micrometer

Mahindra Production

R Record
Manual actions performed with a writing
instrument or marking tool for the purpose of
recording information
Write
Mark

C
52
.1
No
rt
Pa

Mahindra Production

T Think
Refers to the use of sensory mental processes,
particularly those involving visual perception
Inspect
Read

Mahindra Production

Olny srmat poelpe can raed tihs.

cdnuolt blveiee taht I cluod aulaclty uesdnatnrd
waht I was rdanieg. The
phaonmneal pweor of the hmuan
mnid, aoccdrnig to a rscheearch at
Cmabrigde Uinervtisy,
it deosn't mttaer in waht oredr the
ltteers in a wrod are, the olny
iprmoatnt tihng is taht the frist and
lsat ltteer be in the rghit pclae.
The rset can be a taotl mses and
you can sitll raed it wouthit a porbelm.
Tihs is bcuseae the huamn mnid deos
not raed ervey lteter by istlef,
but the wrod as a wlohe. Amzanig huh?
yaeh and I awlyas tghuhot slpeling
was ipmorantt!
Mahindra Production

Index the Sequence Model

Get
Tool

Put
Tool

A B G

A B P

Tool
Action

Aside
Tool

Return

A B P

An operator picks up a job card (located within

reach), reads the instructions (45 words),
and asides the card 3 steps away.
A1 B0 G1 A1 B0 P0 T24 A6 B0 P1 A0 = 340 TMU

Mahindra Production

1. Grasp bolt which is within reach, place it on assembly &

fasten with 12 finger spins
2. Take open end spanner from tool board, tighten a nut with
8 wrist strokes, put spanner again on board.
3. Grasp a T wrench & fasten a bolt with 10 arm turns
& put T wrench aside within reach
4. Grasp pen from pocket & write 5 digits on Traveler card,
keep pen back to pocket.
5. Move to vehicle with 2 steps & read 6 words for model details.
Mahindra Production

Abhay S Lomte
Ext. 8503
M 9422404207
[email protected]
Mahindra Production