In order picking planning, processes for assembling materials based on customer or production requirements are designed with the clear goal of minimizing travel times and maximizing picking rates. This requires an analysis of order structures, an ergonomic layout of the picking zones (shelf-back approach), and the selection of the appropriate picking technology. The MTM method serves as the key to determining objective standard times per pick, as it translates complex reaching, walking, and searching operations into standardized basic movements, thereby ensuring the cost-effectiveness of the picking strategy.
MTM analyses in Production
Using MTM analysis, we break down complex workflows into objective, standardized time modules to streamline your production processes and precisely tap into hidden potential.
Our services for MTM analyses in Production
Conducting MTM time studies
We conduct systematic MTM time studies in which complex manual work processes are methodically broken down into their basic movements and evaluated. This is crucial for replacing subjective estimates with an objective, scientifically sound database that is independent of employees’ individual daily performance. The added value lies in incorruptible transparency, which serves as a reliable foundation for any further process optimization and capacity planning.
Analyses of individual workstations or entire assembly lines
Our experts examine both the micro-motion sequences at specific stations and the complex interactions within interlinked assembly systems. Without this detailed analysis, hidden bottlenecks and local inefficiencies often go unnoticed and impair the entire production flow. Through these levels of analysis, we maximize overall equipment effectiveness (OEE) and ensure that local optimizations also have a positive impact on the entire system.
Objective and transparent identification of time blocks
We break down manual tasks into standardized time units (TMU values) based on internationally recognized standards that can be verified at any time. This standardization is essential for companies to create a “single source of truth” for costing and work planning across different departments. For production optimization, this means enormous planning reliability, as target manufacturing costs can be precisely determined as early as the concept phase.
Maximum leveling to ensure high efficiency
During leveling, we harmonize the workload across all stations to achieve even capacity utilization and perfect production timing. An uneven distribution inevitably leads to costly downtime at one end of the line and stress and quality risks at the other. The result is a smooth, waste-free production process with minimal lead times and optimal utilization of personnel resources.
Design of work processes
We redesign manual processes in assembly, order picking, and shipping from the ground up by directly integrating lean principles with the MTM methodology. This prevents inefficient workflows or search times from arising in the first place and becoming entrenched as the “standard” in production. The added value lies in highly efficient target processes that are designed from day one for maximum value creation and the lowest possible error rates.
Internal benchmarking
By applying uniform MTM standards, we enable direct performance comparisons between different locations, production lines, or shifts within your company. It is only through this comparability that performance gaps are revealed and the true best-practice solutions—which often lie hidden—are identified. For your organization, this means accelerated knowledge transfer and the ability to roll out highly efficient standards globally.
Design of an optimized human-machine interface
We analyze and optimize the interaction between workers and technical systems to ensure that automation and tools optimally support human movement patterns. Poor interface design leads to unnecessary manual steps, cognitive overload, and time losses at the value-adding station. Through MTM-based optimization, we increase process speed while simultaneously reducing the likelihood of errors when operating complex systems.
Development of specifications for equipment
Based on MTM motion studies, we define precise requirements for the procurement of shelving systems, fixtures, and handling equipment in a technical specification. This is important to avoid misguided investments in equipment that looks good in theory but slows down the process in real-world ergonomic applications. You are thus guaranteed that every hardware component you invest in is precisely tailored to your employees’ most efficient movement patterns.
Advantages and benefits of using MTM Time Studies
Even in the early stages of a project, various planning scenarios—such as those for assembly workstations—can be evaluated and optimized, as standardized time modules from a database are used. The work environment does not yet need to be physically set up in the production hall at this stage.
Compliance with target manufacturing costs is ensured in the early planning phase. Wasteful elements in manual workflows are identified (Muda). New opportunities for optimization are identified to further reduce manufacturing costs, thereby increasing efficiency.
Identification of non-ergonomic, tiring work processes as part of a “workload analysis.” This also results in improved acceptance of the workstation among employees.
