Industry Technologies
by Dave Gardner, Editor/Publisher of The Needle’s Eye, assisted by the entire team at Methods Workshop International and by Dr. Mike Fralix of [TC]2.
In the context of work measurement and time standards, MTM stands for Methods-Time Measurement. It is a Predetermined Motion Time System (PMTS) that is used to analyze the basic human movements required to perform specific manual tasks.
By 1950 it was coming into considerable use and, since then, its acceptance and application have spread rapidly, first in the United States and now all over the world. MTM is particularly well adapted to the problems usually encountered by garment manufacturers.
MTM is based on the idea that all manual tasks can be broken down into a series of basic motions, such as reach, move, grasp, and position. Each of these motions has been assigned a predetermined time value, expressed in Time Measurement Units (TMUs). A TMU is defined as 0.036 seconds.
MTM is based on the idea that all manual tasks can be broken down into a series of basic motions, such as reach, move, grasp, and position. Each of these motions has been assigned a predetermined time value, expressed in Time Measurement Units (TMUs). A TMU is defined as 0.036 seconds.
To use MTM, an analyst observes a task being performed and breaks it down into its basic motions. The analyst then assigns a TMU value to each motion based on the type of motion, the distance moved, and the weight of the object being handled. The total TMU value for the task is then calculated by adding up the TMU values for all of the individual motions.
The total TMU value for a task can then be converted into a standard time, which is the estimated time that it should take a qualified worker to perform the task at a normal pace. Standard times are often used to set production quotas, labor costs, and staffing levels.
MTM is a powerful tool for improving work efficiency and productivity. It can be used to identify and eliminate unnecessary motions, develop more efficient work methods, and set realistic production standards. However, MTM is a complex system that requires training and experience to use effectively. Initially, companies were reluctant to use these systems because the time required to analyze an operation was uneconomical. However, this has been overcome by two major factors, (1) the use of industry-specific combination codes reducing the number of code entries and (2) the advent of video recording making it possible to create an operation video library and the ability to analyze operation methods in slow motion.
Even though MTM1 was published in 1948 and its accuracy has been challenged, it remains as the system used to validate all other PMT Systems. Methods Workshop CORE DATA values were validated statistically to reach 99.6% accuracy when compared to MTM1 analysis.
The base system consisted of numerous codes that required the application of variants (i.e. distances, weights, and grasping complexity) by the analyst, which makes it a fairly complex analytical process.
In 1965 an engineered system was developed that added motions that had not been considered in the development of MTM1, such as Step or Pace; Foot Motion; Eye Action; Bend/Arise, and others. The international directorate of MTM released the system as MTM2.
The motion value codes of the Engineered True Cost system developed by Methods Workshop International are based on MTM values and are 99.6% accurate as validated against the MTM1 system and the integrated values of MTM2 for additional motions that were not contemplated in the MTM1 data values.
Some benefits of using MTM are that it:
- Improves work efficiency and productivity by eliminating unnecessary movements and the implementation of Motion Economy principles.
- Eliminates loose and tight rates. This is accomplished by eliminating pace rating. Even the most highly trained engineers struggle to be consistent when pace rating operators. The engineer's mood, attitude towards operators, and the difference between engineers of 100% pace can create unfair standards.
- Allows for more accurate production planning and scheduling ensuring rates are based on international time standards and consistency across all operations.
- Reduces training time and ensures uniform methods by giving trainers a highly detailed method description and video reference.
- Reduces employee fatigue and injuries by creating ergonomically sound methods.
- Allows for more accurate product costing by the creation of an operations database where operations are easily identifiable and easily modified to represent methods of new products.
The MTM founders Harold Bright Maynard, John Lenhard Schwab, and Gustave James Stegemerten are credited with systematically illustrating this for the first time. of the Methods Engineering Council (MEC) during a consultancy assignment at the Westinghouse Brake and Signal Corporation, in the U.S. in the 1940s. This data and the application rules for the MTM system were refined, extended, defined, industrially tested, and documented as a result of further work in later years.
In simple language, it is a "catalog” of times for each motion made by the fingers, hands, arms, legs, and other body members. Just as the inch is a measurement for cloth, the MTM unit is a measurement of operators, whether they are cutters, stitchers, bundlers, pressers, turners, inspectors, or wrappers.
In 1948, Maynard, Stegemerten, and Schwab published their book “Methods-Time Measurement” giving full details of the development of the MTM system and its application rules. The use of MTM spread, firstly in the USA and then to other industrialized countries. In 1951, the USA/Canada MTM Association for Standards and Research was formed by MTM users. The system originators then assigned the MTM copyrights to the MTM Association. Other national MTM Associations were founded and, at a meeting in Paris in 1957, it was decided to form an International MTM Directorate to coordinate the work of National Associations.
Some drawbacks of using MTM are that it:
- Requires training and experience.
- Requires a computer and video equipment.
- Requires the analyst to have expertise in sewing manufacturing.
Despite its drawbacks, MTM is a valuable tool for work measurement and has been used successfully in a wide variety of industries.
Formal Training Providers:
Several organizations and institutions offer training for methods-time measurement (MTM) in the garment industry, catering to different needs and budgets.
Here's a breakdown of some options:
- MTM Associations: The official MTM associations like The Society of Manufacturing Engineers (SME) and the Association of Time and Motion Study (ATMS) offer comprehensive MTM training programs. These programs typically involve instructor-led modules, hands-on workshops, and certification exams. While comprehensive, they can be expensive and time-intensive.
- Independent Consultants: Many experienced MTM practitioners and consultants offer individual or group training programs. This can be a more flexible and cost-effective option, allowing you to tailor the training to your specific needs and the company's garment manufacturing processes.
- Universities and Colleges: Some universities and colleges, particularly those with textile or apparel engineering programs, offer MTM courses as part of their curriculum or as professional development programs. This can be a good option for those seeking academic credit or wanting to integrate MTM into a broader textile/apparel education.
Informal Training Resources:
- MTM Handbooks and Manuals: Several MTM handbooks and manuals provide detailed instructions and time data for various garment-specific motions and tasks. While not a substitute for formal training, they can be valuable resources for self-directed learning or supplementing existing knowledge.
- Online Tutorials and Videos: Some websites and YouTube channels offer free or paid MTM tutorials and video demonstrations. These can be helpful for basic understanding and familiarization with MTM principles but may lack the depth and practical application of formal training.
- Garment Industry Associations and Publications: Industry associations like the American Apparel & Footwear Association (AAFA) and publications like Apparel Resources often share articles, case studies, and best practices related to MTM implementation in garment manufacturing. These resources can provide valuable insights and real-world examples.
Choosing the Right Provider:
The best training provider for you will depend on your specific needs, budget, and learning style. Consider factors like:
- Your level of experience: Are you a beginner, or do you have some prior MTM knowledge?
- Your training goals: Do you need comprehensive certification, basic understanding, or targeted skills for specific garment processes?
- Your budget and time constraints: Can you afford and dedicate time to an extensive program, or do you need a quicker, more affordable option?
- Your preferred learning format: Do you prefer instructor-led sessions, self-directed learning, or a combination?
It's recommended to research different providers, compare their programs, and potentially contact them for more information before making a decision. Remember, the key is to find a training approach that aligns with your specific goals and helps you effectively apply MTM in your garment industry setting.
