Development of Additional Building Block Systems
Development of Additional Building Block Systems
The MTM method continues to undergo constant development. Thus, the MTM basic system became known as MTM-1 and now forms the basis for a large number of standard data developments worldwide. Under the direction of the U.S. MTM Association, GPD (MTM General Purpose Data – 1963) was developed and spread throughout the USA. Based on the relevant research of frequency of motions, the Swedish MTM Association developed MTM-2 (1965), which played an important role in Scandinavia, Great Britain and France. Later, the Swedish MTM Association developed SAM (Sequential Activity and Methods Analysis), a system that enables its users to design work methods for high total productivity, document work methods that can be reproduced with the planned results at any time, and establish norm times based on these documented work methods. Each of these systems was developed based on various principles of combining building blocks of data.
This combination of building blocks can be illustrated as follows:
MTM-2 was developed for processes exhibiting a high method level. The basic values represent a simplified building block system based directly on MTM-1. The following application conditions must be met:
- production with a high degree of repetition
- longer-cycle work processes
- detail-designed processes
- work instructions with precise descriptions of methods
- deviations in the individual operator methods can be detected
Typical application areas exist in companies with high volume or batch production, such as supplier plants for vehicle construction and electronic production.
MTM-UAS was developed for processes exhibiting the characteristic features of batch production. The following should exist as application conditions:
- order-oriented production of a repetitive nature
- repeatable work content despite a large range of product types and varieties
- length of work cycles considerably longer than in high-volume production
- defined general conditions for work processes
- designed processes
- experienced employees
- work instructions without detailed description of methods
Typical application areas exist in companies involved in vehicle construction, supplier plants for vehicle construction, tool building, electronic production and logistics.
MTM-MEK accounts for the special demands of processes exhibiting the characteristics of one-of-a-kind or small batch production. The application conditions can be described through the following aspects:
- order-oriented production of products with little or no repetition
- large number of product types and varieties
- long-cycle or non-cyclic work processes
- constant changes in the work processes and conditions
- relatively low degree of routine
- limited possibilities for detailed work instructions with the associated result of increased variation in the work method
Typical application areas exist in companies involved in machine and steel construction, plant construction, aircraft construction, as well as, in the areas of maintenance and repair, logistics, set-up, and change-over work.
Through aggregation, standard operations for typical activities such as fastening, treating surfaces, tighten and loosen, inspect or measure, assembling standard parts, and transport work were developed for application with MTM-UAS and MTM-MEK basic operations.
Continuing the building block approach, the German MTM Association developed a system for designing, optimizing and quantifying administrative business processes:
MOS The MTM Office System aids in determining the required time for work tasks associated with regularly occurring clerical activities. It can be used in comparing methods and processes as well as in planning and time scheduling or in calculating human resource requirements.
Typical application areas exist in service companies (e.g. credit institutes, insurance companies), administrative groups (e.g. agencies, hospitals) or in the indirect areas of industrial plants (e.g. human resource management, accounting, purchasing).
Among the newest developments of the German MTM Association are MTM Visual Inspection and ProKon.
MTM Visual Inspection
MTM Visual Inspection is a building block system for planning, designing, and assessing times for those visual inspection activities, which depend on human judgment and decision-making. The time required for such activities is the result of a high degree of complex mental processes, thus they cannot be reliably analyzed with the common techniques of time calculation. The latest findings of numerous research projects in industrial science and medicine have been taken into account in developing the building blocks. MTM Visual Inspection also facilitates the proper selection of optic aids such as magnifying glasses, microscopes and monitors, as well as, the design and assessment of visual inspection activities using these aids.
Typical application areas exist in companies with a significant degree of visual inspection activities such as visual inspection;
- of soldered joints or conductor paths on circuit boards
- of coated surfaces
- of molded parts for completeness and surface quality
- of dials and markings on visual devices
- of parts transported on conveyor belts (e.g. bottles, tiles)
ProKon was developed as a tool for use by the design engineers and others in the earliest stages of the product development process. ProKon stands for “Production-Oriented Design”. ProKon is a system for analyzing the ease of assembly of components and parts during product development. The assessment yields constructive approaches for insuring that the final product design meets the need for ease-of-assembly. The assessment is based on a point system, which takes into account manufacturability factors that can be addressed in the product development phase. The quantified assessment of these Influencing Factors provides the engineer with the option of comparing alternative solutions during product development.
The application of ProKon allows for the evaluation of manufacturing costs while in the early stages of product design – all this without detailed knowledge of the expected assembly situation. ProKon can be used to assess newly developed products, as well as, existing products. The Influencing Factors were selected such that the design engineer can make all the necessary decisions quickly and easily with his existing expertise and without additional information.
Standard Operations Logistics
Standard Operations Logistics: MTM can make a valuable contribution in the organization and evaluation of the logistic processes. In the context of the logistic activity in different divisions, many comparable operational sequences occur which have an insignificant variation in time. While such typical operational sequences can vary in their complexity, they can be regarded as standard operations within the overall range of logistics. MTM developed and offers applications for this area, including aggregate building blocks for:
- Transport (activities with different means of transport such as stackers, forklifts, hand pallet trucks, and carriages)
- Handling (handle from boxes, containers, bundles; opening and closing packing containers; information (orders/vouchers) processing)
EAWS The goal of EAWS is to predict, as accurately as possible, the risk for physical strain which can occur during planned activities. Such predictions can be made in the planning phase of production based on pre-established MTM analyses, as well as, in the production phase. Changes to the production plan can then be made to eliminate or reduce detrimental strains and lead to an improvement of the ergonomic design of any production system. In each phase, the connection between
- ergonomic design quality
- required assembly time and
- financial expenses for the work design
is immediately recognizable, thereby making possible a comprehensive, sustainable and optimized design. EAWS works toward this in the following subtasks:
- Prediction of detrimental physical strain while in the production planning phase
- Development of risk assessments to evaluate physical strains
- Evaluation of organizational design methods with regards to physical strain
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Minimizing stress situations
“We’re also carrying out process analyses in the nursing area. This has the crucial benefit that it is easier to plan human resources needs, minimize stress situations and, at the same time, guarantee excellent nursing care or even improve it.”
Dr. Stefan Beyer, Managing Director, Vital-Kliniken GmbH
Ergonomics and economics
“MTM makes a significant contribution towards reconciling an increase in productivity and ergonomics. Because the basis for any increase in productivity is firstly the technical preparation work, the industrial equipment, but also the work design for the employees. When there’s an increase in productivity, there’s greater physical pressure for the employee – and the MTMergonomics analysis allows us to classify the level of this pressure.”
Harald Ebner, Head of Disk Brakes Unit, Knorr-Bremse Systeme für Nutzfahrzeuge GmbH, Aldersbach
"The introduction of the ERGO-UAS system has dramatically changed the way of developing the new products and of managing Production and the Industrial Relations. No motion can be designed, implemented and executed in our company without the scientific assessment of the biomechanical load generated by the motion itself. The paradigm "more productivity less health" has been turned into the new "more productivity more health" and the ERGO-UAS system has become one of the fundamental pillar of our production system"
Luigi Gennaro Galante, VP Manufacturing EMEA, Fiat Group Automobiles SpA