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Methods-time measurement
Methods-time measurement
Methods-time measurement
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Methods-Time Measurement (MTM) is a predetermined motion time system that is used primarily in industrial settings to analyze the methods used to perform any manual operation or task and, as a product of that analysis, to set the standard time in which a worker should complete that task.

MTM was released in 1948 and today exists in several variations, known as MTM-1, MTM-2, MTM-UAS, MTM-MEK and SAM-analysis. Some MTM standards are obsolete, including MTM-3 and MMMM (4M).

History

[edit]

Methods-Time Measurement is a predetermined motion time system that is used to analyze the work methods to perform any manual operation or task and, as a product of that analysis, to set the standard time in which a worker should complete that task.

MTM does not make use of a stopwatch or time study and therefore also negates the need for pace rating.

The basic MTM data was developed by H.B. Maynard, JL Schwab and GJ Stegemerten of the Methods Engineering Council during a consultancy assignment at the Westinghouse Brake and Signal Corporation, United States in the 1940s. This data and the application rules for the MTM system were refined, extended, defined, industrially tested and documented as a result of further work in later years.

In 1948, Maynard, Stegemerten and Schwab published the book “Methods-Time Measurement” giving full details of the development of the MTM system and its application rules. The use of Methods-Time Measurement MTM spread, first in the USA and then to other industrialized countries. In 1951 the USA / Canada MTM Association for Standards and Research was formed by MTM users. The system originators then assigned the MTM copyrights to the MTM Association. Other national MTM Associations were founded; and at a meeting in Paris in 1957, it was decided to form an International MTM Directorate (IMD) to co-ordinate the work of National Associations.

Other MTM based systems have since been developed. MTM-2, a second generation system, was developed under IMD auspices in 1965; MTM–3, a further simplification, was developed in 1970. The original MTM system is now commonly referred to as MTM-1. Other systems based on MTM have been developed for particular work areas by National Associations. The most recent development is MTM-UAS, created by a consortium from the German, Swiss and Austrian National Associations during the mid 1970s. In 1975 the Nordic MTM Association developed and launched MTM-SAM, the third generation of MTM technique.

In 2020 the IMD was terminated and dissolved, and the members split into two groups. The majority of the members (Germany, United States, Italy, Benelux, Brazil, Czechia, Slovakia, China, Hungary, Mexico, South Africa, Austria, Poland and United Kingdom) formed the One-MTM network, headquartered at the MTM ASSOCIATION e.V. in Hamburg, Germany. The minority members formed a new non-profit organization: IMD-EWD was founded by MTM associations Nordic, France, Spain, Turkey and Switzerland. IMD-EWD (International Motion Time Measurement - Ethical Work Design).

MTM Association e.V. is the copyright owner of the following MTM systems: MTM-1®, MTM-2®, MTM-HWD®, MTM-SD®, MTM-UAS® MTM-Logistics, MTM-MEK®, MTM-VI, EAWS®. One-MTM partners develop MTM products and services in the fields of training, consulting, software and research and ensure their uniform application and dissemination worldwide.

Methodology

[edit]

Films were taken using constant speed cameras, running at 16 frames per second, of the work performed by qualified workers on the shop floor at the Westinghouse Brake and Signal Corporation. Each sequence was rated during filming by three qualified Industrial Engineers. These ratings had to agree within a close band, otherwise the sequence was not used.

The rating, or Levelling, system used was the Westinghouse or LMS system – so called after its originators Lowry, Maynard and Stegemerten. This system considers four factors independently:

  • Skill – Proficiency in following the given method
  • Effort – The will to work
  • Conditions – The general work surroundings
  • Consistency – of performance

Each factor is assigned an alpha rating, e.g. “B-“, “C+”, “A”, etc. which has a numeric value which is applied later. This reduces the possibility of “clock rating” and ensures that all factors are considered in the composite rating. Appendix 1 shows the model for Causes of Difference in Output on which the LMS system is based.

Layout, distances, sizes of parts and tools and tolerances were accurately measured and recorded on the shop floor to complement the later analyses.

The films were then projected frame-by-frame and analysed and classified in to a predetermined format of Basic Motions. These Basic Motions were Reach, Grasp, Move, Position, Release, etc. A motion was taken to begin on the frame in which the hand first started performing the motion and was taken to end on the frame in which the motion was completed. This allowed a time for each recorded motion to be calculated in seconds, by means of a frame count, and then “levelled” to a common performance.

Plots of the levelled times for the various motions were drawn. Analysis determined the best definitions of limits of motions and their major, time-determining variables, and resulted in, more or less, the structure which the manual motions of MTM-1 have today. Later work, using Time Study, gave the table of Body Motions.

In 1949, Cornell University conducted an independent study of MTM for the American Society of Mechanical Engineers. It used camera speeds of 64fps. The MTM data was replicated within very close limits. Minor discrepancies revealed by the faster camera speeds have since been corrected in the MTM-1 data.

Detailed research conducted under the auspices of the USA / Canada MTM Association have resulted in minor changes to the data and the application rules and in a greater understanding of the nature of the motions. The last change was made to the detail of the Apply Pressure data in 1973.

Many contributions were developed in the area of MTM, more recently 2019-2020, a team from University of Pisa collaborated with an Italian company developed an automated system called Method Time Measurement 4.0 (MTM4.0) aligning with Industry 4.0 concepts and enabling technologies such as Industrial Internet of Things (IIoT) and Radio Frequency IDentification (RFID), the work of the team is published in International Journal of Productivity and Performance Management.

MTM is complementary to other Industrial Engineering charting analytical techniques; it does not replace them. It should be used after broader techniques have established the Necessity and Purpose, Place, Sequence, Person and Means of the tasks to be evaluated.

Unit

[edit]

The unit in which movements are measured for MTM is the TMU (time measurement unit): 1 TMU = 36 milliseconds; 1 hour = 100,000 TMU.

References

[edit]
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Methods-time measurement

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from Grokipedia
Methods-Time Measurement (MTM) is a (PMTS) used in to analyze manual tasks by dividing them into fundamental human motions and assigning predetermined time standards to each, enabling the establishment of accurate work times without direct observation. Developed in 1948 by Harold B. Maynard, G.J. Stegemerten, and John L. Schwab, MTM builds on earlier motion study principles pioneered by , focusing on optimizing workplace methods to reduce unnecessary movements and improve efficiency. The system was first detailed in the book Methods-Time Measurement by its founders, establishing it as a standardized tool for method analysis in manufacturing and other labor-intensive settings. At its core, MTM operates on the principle that the time for any task is determined by the method employed, emphasizing the breakdown of operations into basic elements such as reach (moving the hand to an object), move (transporting an object), turn (rotating the hand or arm), (securing an object), position (locating or aligning an object), (relinquishing control), and eye times (visual focus and travel). These motions are quantified in Time Measurement Units (TMUs), where 1 TMU equals 0.00001 hours (or 0.036 seconds), allowing for precise calculations based on variables like distance, weight, and precision required. The system includes hierarchical levels, such as MTM-1 for detailed analysis of short-cycle tasks (under 1 minute) and MTM-2 for broader, mid-level evaluations of longer operations. MTM's applications span , , and , where it supports work , enhancement, bottleneck identification, and ergonomic improvements by providing objective data for and labor planning. Globally recognized through organizations like the International MTM Association, it remains a foundational tool for digitizing work standards and fostering competitive in human-centered production.

Overview

Definition and Purpose

Methods-Time Measurement (MTM) is a (PMTS) used in to analyze manual operations by breaking them down into fundamental human motions, such as reaching, grasping, and moving objects, and assigning standardized time values to these motions for establishing work standards without relying on direct timing. This approach ensures that time estimates are based on objective, predefined data rather than variable operator performance, providing a consistent framework for evaluating task efficiency. The core purpose of MTM is to facilitate method improvement and optimization in industrial settings by enabling engineers to and refine work processes proactively, estimate cycle times for tasks, support accurate , and incorporate ergonomic principles to minimize physical strain before tasks are implemented in production. By focusing on the sequence and quality of motions, MTM helps organizations achieve higher productivity, reduce waste, and standardize operations across diverse and assembly environments. In contrast to traditional time studies, which observe and time actual worker performance on existing methods—potentially reinforcing suboptimal habits—MTM emphasizes a method-centric strategy that prioritizes the creation of ideal motion patterns to derive reliable time standards. This proactive orientation allows for the elimination of inefficiencies at the design stage, making MTM particularly valuable for new workflows. MTM traces its origins to early 20th-century motion studies in .

Basic Principles

Methods-Time Measurement (MTM) operates on the core principle that the time required to complete a manual task is fundamentally determined by the method selected for its execution, emphasizing the optimization of work processes through systematic . This approach breaks down tasks into their constituent human motions, classifying them into broad categories such as body movements (e.g., bending or arising), manual actions (involving hand and arm operations like reaching or grasping), and eye movements (such as focusing or traveling to direct attention). By assigning predetermined time values to these elemental motions based on factors like distance, weight, and precision, MTM enables the and improvement of task without relying on direct of actual . The fundamental unit of time in MTM is the Time Measurement Unit (TMU), defined as 1 TMU = 0.00001 hours = 0.036 seconds = 0.0006 minutes. This small increment was specifically chosen to provide high precision when quantifying the brief durations of individual motions, allowing for accurate summation to derive total task times that reflect subtle variations in method. For instance, a simple reach motion might be valued at several TMUs depending on its length and conditions, ensuring that even minor methodological changes can be reliably assessed for time impact. MTM analysis assumes a standard operator—an average performing under normal environmental and physiological conditions—to establish consistent baselines for motion times. This avoids variability from individual differences, focusing instead on the inherent of the motions themselves rather than operator-specific factors. Allowances for , personal needs, and unavoidable delays are not embedded in the elemental motion times but are applied separately after the initial analysis to derive the final , accounting for real-world variability without compromising the method's objectivity. The emphasis remains on dissecting tasks into these elemental motions, promoting a granular understanding that supports method refinement over holistic task timing.

History

Origins and Development

The origins of Methods-Time Measurement (MTM) trace back to the principles of scientific management pioneered in the early . Frederick Winslow Taylor's time studies, initiated in the 1880s and formalized in his 1911 publication , emphasized measuring worker performance to establish efficiency standards in industrial settings. Complementing Taylor's approach, Frank and Lillian Gilbreth developed the concept of therbligs—17 fundamental motion elements—in the 1910s, aiming to analyze and minimize unnecessary movements in tasks through micromotion studies. These foundational ideas shifted focus from subjective observations to systematic work analysis, laying the groundwork for predetermined time systems. MTM's formal development occurred in the 1940s at the Methods Engineering Council (MEC), a consultancy founded by Harold B. Maynard and associates in Pittsburgh, Pennsylvania. Amid World War II's urgent demands for boosted production and standardized labor times, MEC engineers, including Maynard, John L. Schwab, and G.J. Stegemerten, conducted extensive filming of workers primarily under a consultancy assignment for the to decode basic human motions into quantifiable units. This effort addressed limitations in traditional stop-watch timing, such as bias and variability, by creating unbiased, predetermined standards applicable before method implementation. A pivotal milestone came in 1948 with the publication of Methods-Time Measurement by Maynard, Stegemerten, and Schwab through McGraw-Hill Book Company. This 292-page volume detailed the MTM-1 system, the first comprehensive , assigning time values in time measurement units (TMUs) to basic motions based on empirical data from average-skilled workers. The book marked MTM's transition from experimental research to a practical tool for , enabling precise method evaluation without on-site observation. Following , MTM evolved rapidly to accommodate varying analysis needs. By the , the U.S. MTM Association for Standards and Research was established to promote and refine the , while spurred further . In the , MTM-2 emerged as a less detailed for broader applications, officially recognized by the International MTM Federation in , expanding MTM's utility across detail levels from fine manual operations to tasks. This proliferation solidified MTM as a global standard for .

Key Contributors

Harold B. Maynard (1902–1975), an American industrial engineer, served as the lead developer of Methods-Time Measurement (MTM), pioneering its creation in the mid-1940s while working as a consulting engineer at the Methods Engineering Council (MEC), which he founded in 1934 in Pittsburgh, Pennsylvania, as a time study training firm. Maynard, along with his collaborators, developed MTM through a consultancy assignment sponsored by the , focusing on analyzing and standardizing manual work methods to improve industrial efficiency. He authored foundational texts on the subject, including the seminal 1948 book Methods-Time Measurement, co-written with John L. Schwab and G.J. Stegemerten, which formalized the system's principles and data tables. Maynard promoted MTM globally by founding the U.S. MTM Association for Standards and Research in New York in 1951, transferring all rights to the method to ensure its standardization and widespread adoption. John L. Schwab and Gustave J. Stegemerten were key co-developers of MTM, joining Maynard at the MEC in the mid-1940s to contribute to the system's foundational research and documentation. Schwab, an industrial engineer, played a central role in classifying basic human motions into standardized categories, drawing from motion study principles to create the building blocks of MTM analysis. Stegemerten contributed to validating the time values assigned to these motions through empirical studies, ensuring the system's empirical reliability. Together with Maynard, they co-authored the 1948 MTM book, which detailed the methodology and presented time data derived from extensive motion filming and analysis at Westinghouse facilities. The Methods Engineering Council (MEC), comprising Maynard, Schwab, and Stegemerten, conducted empirical studies involving the filming and timing of basic motions to construct MTM's standardized time tables, laying the groundwork for the system's objectivity and reproducibility. This organization transitioned into the broader MTM Association framework, with the U.S. MTM Association established in 1951 to handle international standardization and research. Later, in the 1970s, expansions of MTM variants like MTM-UAS were driven by international MTM associations, including those in , , and , to adapt the system for diverse production contexts such as batch manufacturing.

Methodology

Motion Elements

Methods-Time Measurement (MTM) decomposes manual tasks into discrete motion elements to enable systematic analysis of work processes. These elements capture the fundamental actions performed by the during operations, allowing analysts to identify inefficiencies and optimize methods. In the MTM-1 system, there are 13 basic motion elements, derived by grouping and simplifying the original 18 therbligs—fundamental units of motion developed by Frank and Lillian Gilbreth—into a practical set that balances analytical precision with application efficiency. The primary motion elements focus on hand and arm activities and include Reach (R), which entails extending the hand or fingers to a destination point; Move (M), involving the transportation of an object from one location to another; (G), the act of securing control over one or more objects using the fingers and hand; Position (P), aligning or engaging an object for assembly or use; Release (RL), relinquishing control of an object by opening the fingers; Disengage (D), separating conjoined objects; Turn (T), rotating the hand, , , or body; and Apply Pressure (AP), exerting controlled force to fasten or manipulate. These primary elements are classified according to key criteria that influence their execution, including distance traveled, required accuracy, object weight, and simultaneity with other motions. For example, Reach and Move are subdivided into cases (A through E for Reach, A through C for Move) based on factors like object , precision needs, and clearance tolerances, with distance measured along the path from the hand's starting position. and Position consider object , interference, and fit classes (loose, close, or tight), while Turn accounts for angular degrees (typically in 15-degree increments from 30° to 180°) and weight effects; simultaneity rules adjust for concurrent hand or body actions to avoid overcounting effort. Secondary motion elements address supporting actions beyond basic hand motions, including Eye Travel (ET), the movement of the eyes between fixation points, and Eye Focus (EF), shifting focus to distinguish details; Body Motions (B), such as , twisting, or trunk movements; Foot Motions (F), like operating pedals; and Leg Motions (L), involving steps or knee adjustments. These elements integrate with primary ones to model full-body involvement, classified by distance, direction, and coordination requirements. In , motions are denoted using standardized MTM notation to describe task flows precisely, such as R10C for a Reach of 10 units (e.g., inches or centimeters) to a jumbled or partially obscured object, or combined forms like R10CE to indicate the same reach with concurrent Eye Focus for targeting. This notation facilitates the breakdown of complex operations into verifiable, repeatable components.

Time Assignment and Calculation

In Methods-Time Measurement (MTM), predetermined times are derived from empirical tables established through studies of skilled operators performing basic motions under controlled conditions, using high-speed motion pictures to capture and analyze movements at a level of 100% on the level of manual skills (LMS). These tables provide base time values in Time Measurement Units (TMU), where times vary by factors such as distance, accuracy, and object type; for instance, a Reach (R) motion of 10 inches (25.4 cm) in Case A (clear path, no load) is assigned 6.1 TMU. The assignment process involves breaking down the task into a sequence of basic motions, selecting the appropriate motion code from the tables based on the specific conditions, and adjusting for modifiers that account for simultaneous actions, precision requirements, or environmental factors. For example, if two hands perform symmetric motions simultaneously, the time is typically the value of the dominant motion without additional penalty, but asymmetric bimanual actions may require adding a small modifier such as 2 TMU to reflect coordination demands. The adjusted times for each motion in the sequence are then summed to obtain the total TMU for the task. Total task time is calculated by aggregating the TMUs as follows: Total TMU=∑(base time+modifiers)\text{Total TMU} = \sum (\text{base time} + \text{modifiers}) for all motions in the sequence. This total is converted to seconds using the standard factor of 1 TMU = 0.036 seconds (equivalent to 0.00001 hours), yielding the normal time. Allowances are then added to account for personal needs, , and minor delays, typically at 15% of the normal time for sedentary or light work, resulting in the . Consider a simple one-handed task of picking an easily identifiable object from a table and placing it 10 inches away: (1) Reach 10 inches (R10A: 6.1 TMU), (2) Grasp easy object (G1A: 2.0 TMU), (3) Move object 10 inches (M10A: 6.0 TMU), (4) Position for loose fit (P1SE: 5.6 TMU), (5) Release (RL1: 2.0 TMU). Summing these gives a total of 21.7 TMU, or 0.78 seconds normal time (21.7 × 0.036). Adding 15% allowance (0.12 seconds) yields a of 0.90 seconds.

Applications

Industrial Uses

In manufacturing, Methods-Time Measurement (MTM) is extensively applied for line balancing and establishing time standards in sectors such as automotive and assembly, enabling precise task allocation and optimization. For example, in automotive production, MTM-UAS has been utilized to standardize setup times and reduce changeover durations, facilitating efficient transitions between production runs. Similarly, in manufacturing, MTM systems analyze work cell processes to predict accurate times for repetitive operations, supporting overall and cost estimation. Beyond , MTM finds applications in healthcare for standardizing procedures, such as evaluating the of devices to minimize operational errors and enhance . In , particularly warehouse operations, MTM-Logistics is employed to optimize picking and packing processes, establishing standard times that improve efficiency in environments. In the service sector, MTM supports task design in administrative and service activities, such as filing and , where it breaks down manual operations to streamline processes and reduce variability. MTM integrates seamlessly into broader process improvement frameworks, including , where it complements to eliminate waste and shorten lead times. It also aids assessments by quantifying motion patterns to mitigate repetitive strain injuries, providing engineers with data-driven insights for healthier workstation designs. A in assembly lines demonstrated MTM's impact, where combining MTM-UAS with rebalanced tasks across workstations, increasing output by 11.4% per shift while reducing cycle time disparities. Training in MTM is essential for its industrial adoption, with certification programs offered by the International MTM Association for engineers and practitioners, ensuring standardized application across organizations. These programs equip professionals to develop reliable work standards that contribute to quality management systems, such as those aligned with ISO 9001 requirements for process control and performance evaluation.

Tools and Software

Manual tools for Methods-Time Measurement (MTM) analysis include standardized code charts, such as MTM data cards, which provide tabular representations of motion elements, influencing variables, codes, and time values in time measurement units (TMUs) to facilitate manual breakdown and calculation of tasks. Stopwatches are commonly employed for validation, comparing predetermined MTM times against observed performance to ensure accuracy in real-world applications. Video analysis tools support by recording and replaying operations, allowing analysts to dissect movements frame-by-frame for precise MTM coding and ergonomic assessment. Dedicated MTM software, such as TiCon developed by , automates TMU calculations using MTM building block systems and integrates 3D ergonomics for workplace evaluation, enabling digital and . MTM-compatible programs like Simio facilitate virtual task modeling by incorporating MTM standards to optimize assembly lines and predict metrics. These tools streamline in industrial contexts, such as assembly processes, by simulating motion sequences without physical prototypes. Recent advancements include AI integration for motion recognition, as seen in Khenda's digital tools for MTM-UAS, which accelerate through automated code extraction and guided verification, reducing manual effort. Mobile apps, exemplified by TMU Calculator, enable on-site MTM via tablet interfaces, supporting multiple MTM systems and direct data export for field-based efficiency. Overall, these tools and software significantly MTM , often reducing processing time from hours to minutes while allowing exports to (ERP) systems like for real-time standard setting and integration.

Advantages and Limitations

Benefits

Methods-Time Measurement (MTM) offers significant objectivity in establishing work standards by breaking down tasks into fundamental motion elements with predefined times, thereby eliminating the subjective biases inherent in traditional stopwatch time studies, such as variations due to operator or observer interpretation. This results in consistent standards that can be applied uniformly across different shifts, locations, and operators, ensuring reliability in and reducing disputes over time norms. MTM enables proactive optimization of work methods prior to full-scale production, allowing engineers to identify and eliminate unnecessary motions or inefficiencies early in the design phase, which minimizes waste and associated costs. For instance, by simulating task sequences, MTM facilitates the redesign of processes to avoid reactive adjustments, leading to smoother implementation and lower overall production expenses. The versatility of MTM extends its applicability to a wide range of tasks, including those that are new or previously unmeasured, making it suitable for diverse industries such as and assembly. It supports employee training programs by providing clear, standardized instructions and underpins incentive systems through precise time benchmarks, while delivering quantifiable returns on ; case studies demonstrate gains, such as a 28% reduction in throughput time in an assembly process, enabling higher output without additional resources. From an ergonomic perspective, MTM promotes the selection of safer, more efficient motions during method design, which reduces physical strain in repetitive tasks and lowers rates, such as repetitive strain injuries, by optimizing workstation layouts and movement patterns. This not only enhances worker but also contributes to sustained by minimizing downtime due to issues.

Criticisms and Challenges

One significant criticism of Methods-Time Measurement (MTM), particularly the detailed MTM-1 system, is its time-intensive nature. Analyzing a single minute of repetitive manual tasks using MTM-1 or similar detailed variants can require 200 to 300 minutes of analyst time, often exceeding the duration of traditional time studies for simpler operations. Initial application is especially slow, with analysts able to analyze little more than 30 seconds of operator activity per day in the first weeks of performance due to unfamiliarity with the motion tables. This extended analysis time reduces its practicality for quick assessments, as preparing standard data charts demands substantial effort that may offset anticipated savings. Recent advancements, including Industry 4.0 technologies like AI-assisted motion detection and transcription (as of August 2025), have begun to mitigate these time barriers by automating parts of the analysis process. High training costs further challenge MTM adoption. Certification in MTM-1 typically involves multi-day courses costing between $4,200 and $4,600 as of mid-2025 for participants, including exams and materials, though costs vary by provider and may include discounts (e.g., 30% off select courses booked in late 2025). Analysts require extensive skill development, experience, and judgment to apply the system effectively, often necessitating ongoing maintenance. These demands create barriers, particularly for smaller operations lacking dedicated resources for such investments. MTM's foundational assumptions also limit its accuracy by overlooking individual operator variability. The system presumes a consistent operator rhythm and standardized motions, which does not account for differences between novices and experts or personal factors like and skill levels, leading to discrepancies when validated against actual observations. Elemental time values across MTM variants can vary by more than ±5%, highlighting inconsistencies in handling operator-specific variances. Consequently, MTM proves less reliable for non-repetitive or creative tasks, where motion patterns are irregular and complex, making detailed breakdowns impractical. Critics argue that MTM overemphasizes physical motions at the expense of cognitive and psychological factors. By focusing solely on observable movements, it neglects mental processes, operator stress, or decision-making under pressure, which can significantly influence real-world performance. Additionally, the system's data tables, derived from mid-20th-century studies, often fail to reflect modern tools, , or workplace changes, resulting in outdated time estimates. Adoption challenges persist, especially in small firms. Limited awareness, resource constraints, and high implementation costs hinder MTM use in smaller enterprises, as seen in regions like where it remains underutilized despite potential benefits. Furthermore, the need for updates, such as post-2000 ergonomic revisions integrating systems like SAM (a higher-level MTM variant), underscores ongoing demands to address biomechanical loads and modern production that original tables overlook. These revisions aim to incorporate force and posture considerations but require further validation to maintain MTM's relevance.

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