In manufacturing and operations, profitability rarely depends only on sales. It depends on how efficiently time, labor, and processes are utilized on the shop floor.

A well-executed time and motion study helps organizations eliminate waste, improve labor productivity, and increase capacity utilization—without additional capital investment.

At Faber Infinite Consulting, we have implemented time study in manufacturing across FMCG, packaging, textile, engineering, and logistics sectors. In many projects, structured work measurement study initiatives have improved manpower productivity by 15–30% within 90 days.

This blog explains how to conduct a time and motion study step by step, supported by industry standards, practical experience, and proven frameworks.

What is a Time and Motion Study?

A time and motion study combines:

Component	Definition	Objective
Time Study	Measurement of time taken to complete a task	Establish standard time
Motion Study	Analysis of physical movements involved in a task	Eliminate unnecessary motion
Work Measurement Study	Systematic evaluation of task duration and effort	Improve labor productivity
Method Study	Examination of how a task is performed	Optimize workflow

The concept originated from industrial pioneers like Frederick Winslow Taylor and Frank Gilbreth and later evolved through lean manufacturing principles promoted by organizations such as Toyota Motor Corporation.

Why Conduct a Time and Motion Study?

Benefits in Manufacturing & Operations

Benefit	Impact on Business
Productivity Improvement	10–30% increase in output
Labor Productivity	Reduced idle time
Capacity Utilization	Better machine & manpower usage
Cost Reduction	Lower unit manufacturing cost
Lean Implementation	Eliminates waste (Muda)
Standardization	Creates measurable benchmarks

According to global lean manufacturing practices adopted by Toyota Production System, eliminating non-value-added motion significantly improves operational efficiency.

Step-by-Step Process to Conduct a Time and Motion Study

Below is a structured, practical framework used by Faber Infinite Consulting in industrial time study assignments.

Step 1: Define Objective Clearly

Key Questions:

• What problem are we solving?
• Is it manpower productivity, bottleneck removal, or capacity optimization?
• What KPI will improve?

Action	Output
Define scope	Selected department/process
Set measurable goals	Target % improvement
Identify stakeholders	Production, HR, Maintenance

Practical Insight:

In one FMCG packaging unit, unclear objectives led to incorrect data collection. Once we defined “reduce line changeover time by 20%,” the study became focused and measurable.

Step 2: Select the Process or Task

Choose repetitive, measurable tasks such as:

• Machine loading/unloading
• Assembly operations
• Packaging processes
• Material handling

Selection Criteria

Criteria	Reason
High labor involvement	Maximum impact
Repetitive operations	Reliable data
Bottleneck process	Immediate ROI

Step 3: Break Down the Task into Elements

This is critical in industrial time study.

Divide work into measurable elements:

Example: Carton Packing Process	Element
Pick carton	Element 1
Open carton	Element 2
Insert product	Element 3
Seal carton	Element 4
Place on conveyor	Element 5

Each element must be:

• Clearly observable
• Measurable
• Repeatable

This forms the foundation of motion efficiency study.

Step 4: Conduct Time Observation

Tools Used:

• Stopwatch
• Time study sheet
• Video recording (if permitted)
• Digital time study apps

Types of Time Study Techniques

Technique	Application
Continuous timing	Entire cycle measured
Snapback timing	Each element measured separately
Predetermined motion time systems (PMTS)	Advanced industrial studies

In most shop floors, snapback timing provides better clarity for time study techniques for improving production efficiency.

Step 5: Apply Performance Rating

Not all operators work at the same speed. Therefore:

Standard Time = Observed Time × Performance Rating

Performance Rating Factors:

• Skill
• Effort
• Conditions
• Consistency

Rating	Interpretation
100%	Normal performance
110%	Above average
90%	Below average

Accurate operator performance rating and work measurement methods ensure fairness and transparency.

Step 6: Add Allowances

Allowances account for:

• Fatigue
• Personal needs
• Machine delays
• Contingencies

Typical allowance range: 10–20%

Type	% Range
Personal	5%
Fatigue	4–7%
Delay	3–8%

Standard Time = Normal Time + Allowances

This becomes the benchmark for productivity planning and incentive systems.

Step 7: Conduct Motion Study (Motion Economy Principles)

Now analyze movement efficiency.

Observe:

• Excess walking
• Bending
• Reaching
• Searching for tools
• Double handling

Based on motion economy principles, improvements may include:

Problem	Improvement
Excess walking	Re-layout workstation
Tool searching	Fixed tool location
Bending repeatedly	Height-adjustable table
Double handling	Flow redesign

At Faber Infinite Consulting, layout corrections alone have reduced operator fatigue by 18% in one textile unit.

Step 8: Analyze and Identify Waste

Classify activities:

Activity Type	Value
Value-added	Necessary
Non-value-added	Waste
Necessary non-value-added	Required but non-productive

Lean manufacturing applications of time and motion study help eliminate:

• Waiting
• Over-processing
• Unnecessary motion
• Transportation waste

Step 9: Develop Improved Method

Redesign process based on findings.

Example improvements:

• Combine two elements into one
• Reduce material travel distance
• Introduce jigs or fixtures
• Standardize work sequence

Document new method with:

• SOPs
• Visual aids
• Standard work charts

Step 10: Implement and Monitor

Implementation is where many studies fail.

Key Actions:

Action	Purpose
Train operators	Acceptance
Pilot run	Validate new standard
Monitor KPIs	Measure impact
Continuous review	Sustain gains

In one packaging industry project, after implementing revised standard time, manpower allocation was optimized—saving 12 operators per shift without layoffs.

Difference Between Time Study and Motion Study Explained

Parameter	Time Study	Motion Study
Focus	Duration	Movement
Objective	Set standard time	Eliminate waste
Tool	Stopwatch	Observation & layout
Outcome	Work measurement	Efficiency redesign

Both together form a powerful work-study technique.

Real-World Case Example (Faber Infinite Consulting)

Industry: FMCG
Challenge: Low labor productivity & poor capacity utilization
Approach:

• Conducted industrial time study
• Applied motion efficiency study
• Redesigned layout
• Implemented standard work

Results:

• 22% productivity improvement
• 18% reduction in idle time
• 15% increase in output
• Improved morale due to clear targets

Common Mistakes to Avoid

• Not defining objective
• Observing only one cycle
• Ignoring operator performance rating
• Skipping allowances
• Failing to implement findings

Conclusion: Actionable Takeaways

A structured time and motion analysis is one of the most powerful productivity improvement tools in manufacturing.

Key Takeaways:

✔ Start with a clear objective
✔ Break work into measurable elements
✔ Use correct performance rating
✔ Apply allowances transparently
✔ Improve layout using motion economy principles
✔ Monitor continuously

If implemented correctly, a time and motion study can unlock 15–30% productivity gains without heavy capital investment.

At Faber Infinite Consulting, we help organizations implement scientific work measurement systems that drive measurable, sustainable results.

FAQs

1. How to conduct a time and motion study step by step?

Define objective, select task, break into elements, measure time, apply performance rating, add allowances, analyze motion, redesign method, and monitor results.

2. What is the difference between time study and motion study?

Time study measures task duration, while motion study analyzes physical movement to eliminate inefficiencies.

3. What are the benefits of time and motion study in manufacturing industry?

It improves productivity, reduces costs, enhances capacity utilization, and supports lean manufacturing initiatives.

4. How accurate is a work measurement study?

Accuracy depends on proper sampling, performance rating, and adequate observation cycles.

5. What industries benefit most from industrial time study?

Manufacturing, logistics, FMCG, textile, packaging, engineering, and warehousing sectors benefit significantly.