In today’s fast-moving manufacturing world, staying competitive isn’t just about big investments or flashy technologies—it’s often about squeezing more performance out of what you already have. What if you could cut cycle times, reduce waste, and raise productivity simply by studying how work flows and how people move? That’s the essence of a time and motion study in manufacturing. When done right, it becomes a powerful driver for manufacturing efficiency, lean manufacturing, productivity optimization, and true operational excellence. In this blog, we’ll explore why time and motion analysis matters, how industry-leading systems such as MOST, MTM and MODAPTS are used, and share real-world insights from Faber Infinite’s consulting experience.

Why Time and Motion Study Matters in Manufacturing Efficiency

Time and motion studies examine two key things: how long tasks take (time study) and how work is done (motion study). Together, they provide a scientific basis to improve cycle time reduction, process improvement techniques, work measurement systems, and factory productivity improvement.

• By studying motions and times, you can identify redundant steps, excess transport, poor ergonomics, waiting/idle time—important wastes in a factory.

• Establishing reliable standard times enables capacity planning, staffing, performance benchmarking and operational excellence.

• In a lean manufacturing environment, standardising work (process standardization) and reducing variation are critical. A robust time and motion analysis supports exactly that.

Real-life insight

At Faber Infinite Consulting, we worked with a mid-sized FMCG packaging plant struggling with high labour content and erratic output. A detailed time and motion study revealed multiple minor delays: operators reaching across an aisle for parts, repeated hand motions due to poor layout, machine changeovers taking longer than standard, and inconsistent methods across shifts. We applied predetermined motion time techniques (explained below) to establish new standard times, redesigned the workstation layout (motion economy principles), trained teams to follow the method, and the result was a 12 % reduction in labour minutes per unit and improved throughput by 8 %, without new machinery. This case underlines how small but systematic improvements deliver measurable gains.

Understanding PMTS: MOST, MTM and MODAPTS

Three widely used work measurement systems (predetermined motion time systems—PMTS) are MOST, MTM and MODAPTS. These tools provide high-precision data to support productivity optimization.

MTM (Methods-Time Measurement)

MTM is one of the original and most detailed systems. Tasks are broken down into fundamental motions (reach, move, turn, grasp, release, etc.), each with a time value in TMUs (Time Measurement Units) where 1 TMU = 0.036 seconds approx.
Strengths: Very high precision; ideal for repetitive operations with short cycles.
Limitations: Detailed, time-consuming to apply; may be over-kill for non-repetitive, longer-cycle jobs.

MOST (Maynard Operation Sequence Technique)

MOST simplifies work measurement by using standard sequences (General Move, Controlled Move, Tool-Use) with fewer motion codes.

Strengths: Faster to apply than MTM; well-suited for typical manufacturing or assembly operations.
Limitations: Slightly less granular than MTM; may need adaptation for extremely short or extremely long cycles.

MODAPTS (Modular Arrangement of Predetermined Time Standards)

MODAPTS uses modules (MODs) of time (1 MOD ≈ 0.129 seconds) for basic human motions, with a simpler coding system.
Strengths: Simplified, faster training curve; good for industries requiring quick application.
Limitations: Slightly less detailed than MTM; may not capture ultra-short cycles as granually.

Comparison Table

The Role of Time and Motion Study in Lean Manufacturing & Productivity Optimization

When you integrate time and motion analysis with lean manufacturing, you’re aligning two powerful forces.

• Lean emphasises waste elimination, flow, value-stream thinking, quick changeovers, and continuous improvement. A time and motion study supports this by establishing the “how long” and “how well” baseline.

• Through work measurement systems and motion economy principles, you standardise best methods and set time standards. This enables cycle time reduction, process improvement techniques, and performance benchmarking.

• For example, in a textile industry case, applying MODAPTS across sewing operations helped reduce idle walking and repositioning of materials—resulting in 9 % labour savings and improved first-pass quality.

• In operations where capacity planning and staffing are critical, standard times obtained via PMTS allow industrial engineers to model various scenarios, optimise line balancing, and support robust operational excellence frameworks.

Step-by-Step Guide: Conducting a Time and Motion Analysis in Your Factory

Here is a practical outline you can follow:

1. Scope and select process – Target high-volume, high-cost, or bottleneck operations.

2. Method analysis (motion study) – Observe current method, identify unnecessary motions, apply motion economy principles, redesign workflow.

3. Time measurement – Choose the appropriate measurement system (MTM/MOST/MODAPTS) and capture data.

4. Establish standard time – Sum up element times, add allowances, formalise standard.

5. Implementation & training – Deploy standard work, train operators, visual controls.

6. Monitor, improve, sustain – Use performance benchmarking, continuous improvement methodologies to drive ongoing gains.
By following this structured process, you embed work measurement systems and operational excellence into your manufacturing culture.

Real-World Case Example: Automotive Tier-1 Supplier

One of our clients, a Tier-1 automotive supplier, was facing low output on a manual welding station—cycle time variability and high rework. We applied MOST to define the sequence of motions, redesigned the jig to reduce operator reach, implemented MTM to set a standard time for the station, and introduced visual work instructions. Within three months, throughput improved by 15 % and rework dropped by 25 %. This demonstrates how combining motion (work method), time (standard), lean manufacturing and continuous improvement can drive tangible manufacturing efficiency and productivity optimization.

Benefits of Combining Time Study and Motion Analysis

• Cycle time reduction – shorter, repeatable tasks lead to higher throughput.

• Work method standardisation – consistent output and quality across shifts.

• Labour cost control – accurate staffing, better pricing, fewer overtime hours.

• Improved ergonomics & safety – fewer awkward motions, less fatigue, less downtime.

• Continuous improvement culture – measurable data fosters trust, accountability, and sustained gains.

• Supports Industry 4.0 readiness – accurate standard times feed digital twins, simulation, predictive analytics and smart manufacturing initiatives.

Conclusion & Actionable Takeaways

Time and motion study isn’t an optional extra—it’s a core enabler of manufacturing efficiency, lean manufacturing, productivity optimization, and operational excellence. At Faber Infinite Consulting, we believe the journey to world-class performance starts with understanding how work flows, how people move, and how time is used.
Actionable takeaways for your organisation:

1. Choose one high-impact operation and conduct a motion review.

2. Select the right PMTS (MTM/MOST/MODAPTS) and establish standard times.

3. Implement redesigned work methods, visual controls and standard work instructions.

4. Monitor results monthly and link standard time data to continuous improvement initiatives.

5. Use the insights for capacity planning, staffing, cost modelling and performance benchmarking.
   By making this investment, you don’t just improve one line—you shift your culture toward higher performance, sustainability and operational excellence.

FAQs

Q1. What is the importance of time and motion study in manufacturing?
A: It provides a structured way to analyse how work is done (motion) and how long it takes (time). This insight underpins process improvement techniques, cycle time reduction, work measurement systems and productivity optimization.

Q2. How do MOST, MTM, and MODAPTS improve manufacturing efficiency?
A: These predetermined motion time systems break down tasks into elemental motions, assign standard times, and enable consistent measurement and improvement. MOST is faster for typical tasks, MTM is very detailed, MODAPTS is simpler and quicker to apply.

Q3. What is the difference between MOST, MTM and MODAPTS work measurement systems?
A: MTM offers high precision by analysing every motion but takes longer to apply. MOST simplifies and uses standard sequences. MODAPTS uses modular units (MODs) and is fastest to deploy. Each has trade-offs between speed and detail.

Q4. How does a time and motion study support lean manufacturing?
A: Lean manufacturing focuses on flow, waste elimination and standard work. Time and motion study provides the data to standardise methods, reduce non-value-added motion, set reliable cycle times, and manage continuous improvement.

Q5. What are the best work measurement methods for manufacturing improvement?
A: The “best” method depends on your context—volume, variability, cycle time, repeatability. For high-volume short-cycle tasks MTM or MOST might be best; for tasks needing quick rollout and training MODAPTS may be ideal. A tailored approach aligned with your improvement goals ensures the biggest benefit.

Contact us