Maximizing Operational Excellence with Predetermined Motion Time Systems

For companies looking to streamline work and maximize output, predetermined motion time systems (PMTS) have proven very useful. PMTS is a methodical way to analyze and quantify the basic human movements involved in manual tasks.

By breaking jobs down into their fundamental motions, like reaching or moving, and assigning set time values to each movement, PMTS allows precise calculation of standard times for any given task.

This data-driven approach does away with the inaccuracies of older timing studies while also providing a full understanding of how work gets done. This informs good decision-making and process optimization.

The origins of Predetermined Motion Time Systems (PMTS) can be traced back to pioneering researchers Frank and Lillian Gilbreth. They introduced the idea of analyzing “therbligs” – the basic elements of manual labor. They used motion capture techniques to study movement patterns.

Today’s PMTS methods have evolved to cover a wide range of uses, from setting labor standards and costs to production line balancing and ergonomic analysis. It helps businesses in countless ways.

Key Highlights

• Overview of Predetermined Motion Time Systems (PMTS) and their applications in industrial operations
• Detailed exploration of PMTS development techniques.
• Guidance on selecting the appropriate Predetermined Motion Time Systems (PMTS) based on operational requirements, cost considerations, and performance levels.
• In-depth analysis of PMTS applications in enhancing work methods.
• Examination of industry adoption and implementation, with a focus on labor-intensive sectors, supply chain management, and global retail
• Discussion of limitations and challenges associated with Predetermined Motion Time Systems (PMTS).
• Insights into future trends and advancements.

Unraveling the Power of Predetermined Motion Time Systems (PMTS)

Predetermined Motion Time Systems (PMTS) have emerged as a powerful tool for streamlining workflows and maximizing productivity.

At its core, a PMTS is a systematic approach to analyzing and quantifying the basic human movements involved in manual tasks. 

This data-driven approach not only eliminates the inherent inaccuracies associated with traditional time studies but also provides a comprehensive understanding of how work is accomplished, enabling informed decision-making and process optimization.

The origins of Predetermined Motion Time Systems (PMTS) can be traced back to the pioneering work of Frank and Lillian Gilbreth, who introduced the concept of “therbligs” – the fundamental elements of manual labor – and the use of chronocyclograph techniques to study motion patterns. 

Building upon this foundation, modern PMTS methodologies have evolved to encompass a wide range of applications, from establishing labor standards and costing to production line balancing and ergonomic analysis.

Definition and Overview

A Predetermined Motion Time System (PMTS) is a work measurement technique that analyzes the basic human movements required to perform specific manual tasks in a given environment. 

It involves breaking down a task into its fundamental motions and assigning predetermined time values to each motion based on extensive research and data compilation. By summing these time values, Predetermined Motion Time Systems (PMTS) provides an accurate and consistent standard time for completing the task.

Fundamental principles and objectives

The fundamental principles underlying Predetermined Motion Time Systems (PMTS) revolve around two key objectives: work measurement and labor costing. 

By accurately quantifying the time required for manual operations, PMTS enables organizations to establish precise labor standards, optimize production schedules, and calculate labor costs with a high degree of accuracy. 

This data-driven approach is particularly valuable in labor-intensive industries, where labor costs can significantly impact profitability and competitiveness.

Historical evolution

The roots of PMTS can be traced back to the pioneering work of Frank and Lillian Gilbreth, who introduced the concept of “therbligs” – the fundamental elements of manual labor – in the early 20th century. 

Their groundbreaking research involved using chronocyclograph techniques to capture and analyze motion patterns, laying the foundation for modern PMTS methodologies. 

The Gilbreths’ insights into motion economy and the systematic study of human movements paved the way for the development of various PMTS systems, such as Methods-Time Measurement (MTM) and Maynard Operation Sequence Technique (MOST), which are widely used in industries today.

The Art of Developing a Predetermined Motion Time Systems (PMTS)

Developing a robust and accurate Predetermined Motion Time System (PMTS) is a meticulous process that requires a deep understanding of human motion, statistical analysis, and data compilation. 

It involves breaking down complex tasks into their fundamental movements, meticulously studying these movements, and assigning predetermined time values based on extensive research and validation. 

This process is an art in itself, combining scientific rigor with a keen eye for detail and a profound appreciation for the nuances of human motion.

Data Collection and Analysis Techniques

Micro-motion study

Originally PMTS development lies in the micro-motion study, a technique that involves meticulously analyzing and recording the smallest movements involved in a task. 

This process often involves videotaping workers performing tasks under normal operating conditions, allowing researchers to dissect every motion in slow motion and with granular detail. 

To facilitate accurate time measurement, PMTS systems frequently employ time measurement units (TMUs), which are smaller units of time measurement then seconds, enabling more precise calculations without the use of lengthy decimals.

Basic human movements

PMTS systems are built upon the fundamental premise that all manual tasks can be broken down into a series of basic human movements, such as reaching, moving, engaging, or disengaging. 

These basic movements are common across a wide range of industrial operations and form the building blocks of more complex tasks. 

By identifying and quantifying the time required for these basic movements, PMTS systems can accurately predict the overall time required for any manual task by summing the individual movement times.

Compiling time value charts and databases

Once the basic human movements have been identified and their time values determined through extensive research and analysis, the next step in developing a Predetermined Motion Time System (PMTS) is to compile these time values into comprehensive charts and databases. 

These resources serve as the foundation for applying the PMTS to real-world scenarios, allowing analysts to quickly reference predetermined time values for specific movements and calculate standard times for complex tasks by combining the individual movement times.

Selecting the Right Predetermined Motion Time System (PMTS)

Cost of Installation and Operational Costs

When considering the implementation of a PMTS within an organization, one of the critical factors to evaluate is the associated costs. 

The cost of installation involves procuring the necessary software, hardware, and training resources, as well as engaging experts to guide the initial setup and implementation. 

Level of performance and consistency

Different PMTS systems offer varying levels of accuracy and consistency in their time standards. 

Some systems are designed for general use and can be applied to a wide range of industrial operations, while others are more specialized and tailored to specific types of tasks or environments. 

When selecting a Predetermined Motion Time System (PMTS), it is crucial to evaluate the level of performance and consistency required for your specific operations and ensure that the chosen system aligns with those needs.

Nature of operations

The nature of the operations being performed within an organization is a key consideration when selecting a PMTS. 

PMTS systems are particularly well-suited for manual, repetitive tasks that involve a series of defined movements. 

If your operations involve a significant amount of non-repetitive or highly variable tasks, a PMTS may not be the most appropriate solution, and alternative work measurement techniques may need to be explored.

Applications and Benefits of Predetermined Motion Time Systems (PMTS)

The applications and benefits of Predetermined Motion Time Systems (PMTS) extend far beyond the realm of work measurement and labor costing. 

These powerful systems have the potential to transform virtually every aspect of industrial operations, from enhancing work methods and streamlining measurement processes to improving ergonomics and supporting strategic planning. 

By leveraging the power of PMTS, organizations can unlock a wealth of opportunities for optimization, efficiency, and competitive advantage.

Enhancing Work Methods

Methods Improvement and Evaluation

One of the primary applications of PMTS is in the realm of work methods improvement and evaluation. 

By accurately quantifying the time required for each motion within a task, Predetermined Motion Time Systems provides a comprehensive understanding of the entire process flow. 

This insight enables organizations to identify bottlenecks, inefficiencies, and areas for potential improvement. 

Aiding in design and training

PMTS also plays a crucial role in the design and development of tools, jigs, and other equipment used in industrial operations. 

By analyzing the motion patterns and time requirements of various tasks, PMTS can inform the optimal design of these tools and equipment, ensuring ergonomic considerations are addressed and motion efficiency is maximized.

Streamlining Work Measurement

Establishing Time Standards and Labor Costs

One of the primary objectives of Predetermined Motion Time Systems (PMTS) is to establish accurate and consistent time standards for manual tasks. By precisely quantifying the time required for each motion, PMTS provides a reliable foundation for setting labor standards and calculating labor costs. 

This data-driven approach eliminates the need for subjective assessments and ensures that labor costs are accurately reflected in pricing, budgeting, and operational planning.

Balancing production lines

In industries where assembly lines or production lines are prevalent, PMTS plays a vital role in balancing and optimizing these processes. 

By accurately determining the time required for each task along the line, PMTS enables organizations to identify bottlenecks, redistribute workloads, and optimize line layouts for maximum efficiency. 

This not only improves productivity but also minimizes waste and enhances overall operational effectiveness.

Auditing and checking time study standards

Predetermined Motion Time Systems (PMTS) can also serve as a valuable tool for auditing and verifying time study standards that have been established through traditional methods. 

By comparing the PMTS-derived time values with existing standards, organizations can identify discrepancies, validate the accuracy of their data, and make informed decisions regarding potential adjustments or revisions.

Advantages Over Traditional Time Studies

Eliminating timing inaccuracies and performance rating

One of the most significant advantages of PMTS over traditional time studies is the elimination of timing inaccuracies and the need for subjective performance ratings. 

Unlike stop-watch time studies, where human error and subjective assessments can introduce inaccuracies, PMTS relies on predetermined time values that have been rigorously researched and validated. 

This approach ensures consistency and removes the potential for bias or inconsistencies in performance rating.

Predetermining times for planning and costing

Another key advantage of Predetermined Motion Time Systems (PMTS) is the ability to predetermine time values for tasks before they are performed. 

This capability is invaluable for planning and costing purposes, as it allows organizations to accurately estimate labor requirements, production schedules, and associated costs well in advance. 

Consistency and method-consciousness

PMTS systems enforce a consistent and structured approach to work measurement, ensuring that all tasks are analyzed and evaluated using the same methodology and standards. 

This consistency not only enhances the reliability of the data but also promotes “method-consciousness” throughout the organization. 

By understanding the significance of each motion and its impact on overall efficiency, workers and managers alike become more attuned to the importance of optimizing work methods and adhering to best practices.

Industry Adoption and Implementation

The transformative power of Predetermined Motion Time Systems has not gone unnoticed across various industries, with organizations recognizing the potential for improved efficiency, cost savings, and competitive advantage. 

From labor-intensive sectors to global supply chains and retail, the adoption and implementation of PMTS have gained significant traction, driven by factors such as sustainability initiatives, occupational safety concerns, and the ever-increasing demand for agility and responsiveness.

Labor-Intensive Industries

Living Wage Movement and Sustainability

In labor-intensive industries such as apparel, footwear, and manufacturing, the implementation of Predetermined Motion Time Systems has taken on added significance in recent years. 

The Living Wage movement, which advocates for fair and livable wages for workers, has highlighted the importance of accurate labor costing and wage determination. 

Occupational safety, ergonomics, and job satisfaction

Beyond labor costing and wage determination, PMTS also contributes to improving occupational safety, ergonomics, and job satisfaction within labor-intensive industries. 

By analyzing the motion patterns and time requirements of various tasks, PMTS data can inform the design of workstations, tools, and processes that prioritize ergonomic considerations and minimize the risk of repetitive strain injuries or other occupational hazards.

Global Supply Chain and Retail

Canadian Apparel Federation (CAF) and SewEasy PMTS

Recognizing the importance of PMTS in the global supply chain and the demands of the fast fashion industry have underscored the importance of agility and responsiveness in production planning and costing. 

The Canadian Apparel Federation (CAF) has been at the forefront of exploring and promoting the adoption of PMTS solutions, recognizing their potential to streamline operations and enhance competitiveness.

One notable initiative undertaken by the CAF was the organization of a webinar series focused on the SewEasy PMTS software system, which is based on the widely adopted Methods-Time Measurement (MTM) standard.

By educating their members on the capabilities and benefits of PMTS, the CAF aimed to equip apparel manufacturers with the tools and knowledge necessary to optimize their production processes and adapt to the ever-shortening life cycles of fast fashion products.

Fair Wear Foundation (FWF) and labor minute costing calculators

Beyond the apparel industry itself, PMTS has also garnered attention from organizations dedicated to promoting fair labor practices and sustainable supply chains. 

The Fair Wear Foundation (FWF), a non-profit organization committed to ensuring safe, dignified, and properly paid employment in the garment industry, has leveraged the power of Predetermined Motion Time Systems (PMTS) to develop country-specific labor minute costing calculators.

These calculators, based on the SewEasy PMTS approach, provide a comprehensive framework for determining fair and livable wages for garment workers across various regions. 

By accurately quantifying the time required for various production tasks, the FWF’s labor minute costing calculators enable fashion retailers and brands to make informed decisions about pricing, sourcing, and ensuring ethical labor practices throughout their supply chains.

Limitations and Challenges of Predetermined Motion Time Systems

While the benefits and applications of PMTS are numerous and far-reaching, it is essential to acknowledge the limitations and challenges associated with these systems. 

As with any tool or methodology, Predetermined Motion Time Systems has its inherent constraints and considerations that must be carefully evaluated and addressed to ensure optimal implementation and effectiveness.

Restricted Applications

Manual and repetitive operations only

One of the primary limitations of PMTS is its focus on manual and repetitive operations. 

While this focus is well-suited to many industrial settings, it can pose challenges in environments where tasks are highly variable, non-repetitive, or involve complex cognitive processes. 

In such scenarios, the predetermined time values derived from PMTS may not accurately reflect the true time requirements, leading to potential inaccuracies in work measurement and labor costing.

Limitations for non-repetitive or restricted work

Similarly, Predetermined Motion Time Systems may not be the most appropriate solution for work that is performed in restricted or confined spaces, or for tasks that involve unusual body postures or ergonomic challenges. 

In these cases, the predetermined time values may not adequately account for the additional time and effort required, potentially leading to underestimations of labor requirements and costs.

Training and Expertise Requirements

Need for trained personnel and judgment

Successful implementation and utilization of PMTS require a significant investment in training and expertise. 

While PMTS systems are designed to minimize subjectivity, there is still a need for trained personnel who can exercise sound judgment in applying the systems appropriately. 

This includes accurately identifying and classifying the various motions involved in a task, as well as interpreting and applying the predetermined time values correctly.

Future Trends and Advancements in Predetermined Motion Time Systems (PMTS)

As technology continues to advance and industrial practices evolve, the field of PMTS is poised for significant growth and innovation. 

From the integration of automation and digitization to the expansion of specialized systems and hybrid approaches, the future of Predetermined Motion Time Systems promises to unlock new frontiers in work measurement, process optimization, and operational efficiency.

Integration with Automation and Digitization

Robotics and Industry 4.0 Implications

One of the most exciting developments in the realm of PMTS is its integration with automation and robotics. 

As Industry 4.0 concepts gain traction, the lines between manual and automated processes are becoming increasingly blurred. 

PMTS systems will need to adapt to this new reality, incorporating methodologies for analyzing and quantifying the time requirements of human-robot interactions, as well as the time required for programming, setup, and maintenance of automated systems.

Expanding Scope and Adaptability

Specialized systems

While traditional PMTS systems have primarily focused on manual, repetitive tasks, the future holds promise for the development of specialized systems tailored to unique operational environments. 

For instance, dedicated PMTS solutions for clerical work, machine operations, or even highly specialized tasks such as microscopic assembly could emerge, enabling organizations to leverage the power of work measurement across a wider range of applications.

Hybrid approaches and customization

The future may see a rise in hybrid approaches that combine Predetermined Motion Time Systems with other work measurement techniques, such as time studies or simulation models. 

These hybrid methodologies could provide a more comprehensive and holistic view of operational performance, accounting for both manual and non-manual tasks, as well as enabling customization to specific organizational needs and requirements.

Conclusion

Predetermined motion time systems (PMTS) have proven incredibly useful. 

By blending science with a deep understanding of human movement, these systems enable organizations to precisely calculate times for manual jobs, set clear labor standards, optimize workflows, and make informed decisions about resource allocation and costs.

From labor-intensive industries like clothing and footwear manufacturing to global supply chains to retail stores, adopting PMTS has gained strong traction. 

Drivers include sustainability goals, worker safety concerns, and the constant need for flexibility and quick response in today’s fast-moving business environment.

It’s important to acknowledge PMTS limitations, like focusing on repetitive manual work. Expertise and training are also needed for proper use.

By addressing challenges and evolving with emerging tech like automation, specialized systems, and blended approaches, PMTS’ future promises new frontiers in work analysis, process refinement, and operational excellence. 

Continuous adaptation keeps Predetermined Motion Time Systems (PMTS) working wonders for organizations worldwide.