In today’s competitive manufacturing environment, productivity improvement is no longer optional — it is survival. Rising labor costs, tight delivery schedules, and margin pressure demand scientific performance measurement.
At Faber Infinite Consulting, we have seen firsthand how a structured time and motion study can unlock 15%–35% productivity gains without major capital investment. This blog explores real case studies, proven frameworks, and expert-backed methodologies that demonstrate how time study in manufacturing transforms operational performance.
What Is a Time & Motion Study?
A time and motion study is a structured work measurement study used to analyze the time taken to perform tasks and evaluate the efficiency of movements involved.
| Component | Focus Area | Outcome |
| Time Study | Measures task duration | Standard time setting |
| Motion Study | Analyzes operator movements | Eliminates wasteful motions |
| Industrial Time Study | Applied in production setups | Improves labor productivity |
| Work Measurement | Establishes performance benchmarks | Capacity utilization planning |
The concept was pioneered by Frederick Winslow Taylor and later expanded through motion efficiency research by Frank B. Gilbreth and Lillian M. Gilbreth.
Today, it is a core component of Lean Manufacturing, endorsed by global bodies such as International Labour Organization for systematic work-study techniques.
Why Time & Motion Study Matters Today
According to research by McKinsey & Company, manufacturing productivity can improve by 20–30% through structured operational optimization.
Our experience across FMCG, automotive, packaging, and process industries confirms similar outcomes when industrial time study is implemented correctly.
Key benefits include:
- Accurate operator performance rating and work measurement methods
- Improved capacity utilization
- Reduced idle time
- Balanced line efficiency
- Improved labor productivity
- Scientific manpower planning
Real Case Studies: Productivity Gains Through Time & Motion Study
Below are real-world examples from Faber Infinite Consulting engagements.
Case Study 1: FMCG Packaging Unit (India)
Problem
- Frequent line stoppages
- Unbalanced operator workload
- 68% line efficiency
Approach (Time and Motion Analysis)
| Step | Action Taken | Method Used |
| 1 | Conducted stopwatch-based time study | Industrial time study |
| 2 | Broke task into micro-motions | Motion efficiency study |
| 3 | Applied motion economy principles | Method study |
| 4 | Set revised standard cycle time | Work measurement |
Findings
- 22% non-value-added motion
- 15 seconds excess handling per carton
- Poor workstation layout
Results
| KPI | Before | After | Improvement |
| Line Efficiency | 68% | 84% | +16% |
| Labor Productivity | Baseline | +21% | Significant |
| Capacity Utilization | 72% | 88% | +16% |
Outcome: 21% productivity improvement without hiring additional manpower.
Case Study 2: Automotive Component Manufacturer
Challenge
- Low throughput
- High operator fatigue
- Unclear standard times
Intervention: Time Study Techniques for Improving Production Efficiency
We implemented:
- Detailed time study in manufacturing
- Performance rating factor (PRF) adjustments
- Allowance calculation (fatigue, delay, personal time)
| Study Parameter | Observation |
| Average Cycle Time | 58 sec |
| Normal Time | 52 sec |
| Standard Time | 60 sec |
Improvements
- Optimized workstation layout
- Reduced motion travel by 30%
- Introduced two-handed process balancing
Results
- 18% output increase
- 12% reduction in fatigue complaints
- 15% labor cost optimization
Case Study 3: PP Woven Packaging Plant
Issue
- Overstaffed departments
- Idle machine waiting time
- Low OEE (Overall Equipment Effectiveness)
Solution: Lean Manufacturing Applications of Time & Motion Study
| Action | Outcome |
| Motion study for loom changeover | Reduced setup time by 25% |
| Standard time calculation | Improved manpower planning |
| Line balancing | Reduced bottleneck delays |
| Idle time mapping | Reallocated 8 operators |
Results
- 23% manpower productivity increase
- 20% improvement in machine uptime
- 14% cost savings in 6 months
How to Conduct a Time & Motion Study Step by Step
Here is a simplified implementation roadmap:
| Step | Description | Tools Used |
| 1 | Select process | Value stream mapping |
| 2 | Break into elements | Method study |
| 3 | Measure time | Stopwatch / video |
| 4 | Apply performance rating | Operator performance rating |
| 5 | Add allowances | Work measurement standards |
| 6 | Set standard time | Industrial time study |
| 7 | Improve layout & method | Motion economy principles |
| 8 | Monitor results | KPI dashboards |
Difference Between Time Study and Motion Study Explained
| Parameter | Time Study | Motion Study |
| Focus | Time duration | Movement efficiency |
| Objective | Set standard time | Reduce wasted motion |
| Output | Standard time sheet | Optimized method |
| Tools | Stopwatch, software | Video analysis, ergonomics |
Both together form time and motion analysis, a powerful productivity improvement tool.
Expert Insights & Industry Standards
The International Labour Organization (ILO) recommends work-study techniques to improve industrial competitiveness.
Research from Harvard Business Review highlights that data-driven performance management significantly improves operational results.
In Lean systems inspired by Toyota Motor Corporation, standardized work and motion optimization are foundational to achieving operational excellence.
At Faber Infinite Consulting, we integrate:
- Lean Manufacturing
- TPM (Total Productive Maintenance)
- Standardized Work
- Industrial Engineering tools
- Digital time study software
Benefits of Time & Motion Study in Manufacturing Industry
| Benefit | Business Impact |
| Improved labor productivity | Higher output per employee |
| Reduced cycle time | Faster deliveries |
| Better manpower planning | Controlled labor cost |
| Scientific performance targets | Fair evaluation |
| Increased capacity utilization | Improved ROI |
| Reduced fatigue | Safer workplace |
Common Mistakes to Avoid
- Measuring without method study
- Ignoring performance rating
- Not including allowances
- Poor communication with operators
- Treating it as a cost-cutting exercise only
Trust and transparency are critical for success.
Actionable Takeaways
- Start with one critical bottleneck process.
- Conduct structured work measurement study.
- Apply motion economy principles.
- Set realistic standard times.
- Align with Lean manufacturing goals.
- Track productivity weekly.
- Reinforce with continuous improvement culture.
When done correctly, time and motion study becomes a strategic growth accelerator — not just an industrial engineering tool.
FAQs
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What is the main purpose of a time and motion study?
It helps measure task duration and eliminate inefficient movements to improve labor productivity and capacity utilization.
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How long does it take to conduct an industrial time study?
Typically 1–4 weeks depending on process complexity and data collection scope.
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What is the difference between time study and motion study?
Time study measures task duration; motion study analyzes movement efficiency. Together they optimize work methods.
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Can time study be applied in non-manufacturing sectors?
Yes. It is widely used in logistics, healthcare, warehouses, and service operations.
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Is time and motion study relevant in Lean manufacturing?
Absolutely. It supports standardized work, waste elimination, and continuous improvement.
