Imd Presentation Dec 2008.V01

December 2008 From the desk of G. Caragnano, IMD Executiv e Director 1

IMD objectives and activities

December 2008


IMD Mission and Goals

l IMD is dedicated to achieve global leadership and to create value for its two major stakeholders:

1. National MTM Associations2. MTM applicators and instructors (companies,

institutions and individuals)


IMD active membersWEB or Email addressFoundation dateNational MTM Association

www.cpns.co.yu2004Serbia and Montenegro MTM Association

www.mtmdobrasil.com2004Brazilian MTM Association

www.plmtm.com2004Polish MTM Association

[email protected] MTM Association

www.mtm-vereinigung.at2000Austrian MTM Associationwww.mtmitalia.it1998Italian MTM Association

www.asocmtmesp.com1990Spanish MTM Association

www.mtm-association.org.za1975South African MTM Association

www.ukmtma2000.co.uk1964U.K. MTM Association

[email protected] MTM Association

www.dmtm.com1962German MTM Association

www.mtmfr.com1957French MTM Association

www.swissmtm.com1957Swiss MTM Association www.mtmnorden.com1955Nordic MTM Association

www.mtm.org1951U.S.A. and Canada MTM Association


Potential next IMD members

l Chinal Portugal

l (at present is a German Chapter)

l Indial Russia


IMD Organisation


The role of MTM today


Others5%

France8%

Germany25%

Sweden24%

UK13%

USA25%

The use of MTM is expanding globallyNumber of MTM certified practitoners

0

99.321

194.520

221.700

160.544

0

50.000

100.000

150.000

200.000

250.000

1965 1975 1985 1995 2003

year

Nr.M

TM c

ertif

icat

es


MTM in the past

“You can get any color, as long as it's black.”

MTM was used to design efficient working methods, to optimize production steps where labor is used extensively and to get a scientific measure of work (standard time).

Focus on Focus on labor labor

productivityproductivity


MTM today

l Identifying and Eliminating MUDA in production and logistic processes

l Balancing the work flow

l Designing new methods in the earliest stage of product development

l Defining cycle times and Takt

l Improving health, safety and satisfaction (ERGONOMY)

l Reducing Change-Over times

l Improving Quality

MTM is used to design efficient and standardized working methods in order to support WCM and Lean implementation, by


Official MTM Systems

Global platform


MTM specific data catalogues

Basic motions

Motion seq.

Basic operat.

Operations

Op. sequence

MTM Base(MTM-1)

MTM-2

UAS/SAMMEK

MEKData Blocks

UAS Data BlocksSAM open patterns

Mass productionBatchproduction

One of a kindproduction

6

5

4

3

2

1

Time elements

Method level

Data level

Functions

Official MTM platformOfficial MTM platformAnalysis speed

1/300

1/100

1/10

LOW HIGH


Application examples

f SX TMU DX f f SX TMU DX f f CODE TMU f CODE TMU f CODE TMUReach 2 screws (jumbled) to 60 cm R60C 22,3 R60C GC80 32,0 GS80 25 AF3 80 AB3 90Grasp screws G4B 9,1 14,0 GC5 GS10 10 AF1 40 AB3 90

9,1 G4BMove to threaded holes (55 cm) M55C 23,5 M-B PC80 41,0 PP80 40Position P2SE 16,2 PP10 25

11,4 ET 30/40 7,0 E4,5 M4C 21,0 PC516,2 P2SE

Search for thread 2 M2B 4,0 M2B 2 2 PA5 6,0 PA5 2First fastening motion M4B 4,0 M4B PA5 3,0 PA5Motion cycle 5 RL1 10,0 RL1 5 5 GB5 35,0 GB5 5 6 SA15 90 6 ZB1 60 6 ZA 60(5 hand motions) 5 R4A 17,0 R4A 5 5 PA5 15,0 PA5 5

5 G1A 10,0 G1A 55 M4B 20,0 M4B 5

RL1 2,0 RL1Reach screwdriver to 35 cm 14,2 R35B 18,0 GB45 GS45 20 HC2 70 HB3 100

2,0 G1AMove to first screw (35 cm) 16,8 M35C 36,0 PC45 PP45 35Position 19,7 P2SSEPT 50,0 PT 50,0 PT PT 50 PT 50 PT 50Move to second screw 16,8 M35C 36,0 PC45 PP45 35 PC2 40 PB3 50

19,7 P2SSE50,0 PT 50,0 PT PT 50 PT 50 PT 50

Screwdriver aside 6,8 M10B 6,0 PA15 PD10 102,0 RL1

TMU 377,3 370 390 390 490SEC 13,58 13,32 14,04 14,04 17,64

MEKDescription MTM-1 MTM-2 SAM UAS


MTM QUALIFICATION MINIMUM REQUIREMENTS AND STANDARD PATTERN

QualificationMinimum Duration

Recomm. Duration Content

Compulsory Precedence

Reccomended Precedence

2 days 3 days MTM-1 system introduction

- 1 dayergonomic norms in workplace design and ergonomic risk assessment

- 1 day productivity improvement10 days 15 days MTM-1 theory and examination

- 1 dayergonomic norms in workplace design and ergonomic risk assessment

- 1 day productivity improvement3 days 3 days Theory + Examination

2 days Practice + Principles of data construction

3 days 3 days Theory + Examination

- 2 daysPractice + Principles of data construction + level 2 (data-blocks)Theory + practiceExamination

2 daysPractice + Principles of data construction + level 2 (data-blocks)

4 4 days Theory + practice + Examination

1 days ERGO-SAMMTM-SAM Practitioner

MTM-UAS Practitioner (level 1)

MTM-MEK Practitioner(level 1)

3 days 3 days

MTM BASE MTM-1 Practitioner

MTM BASE MTM-1 Practitioner

MTM-1 Practitioner

MTM BASE

MTM-2 Practitioner MTM BASE MTM-1 Practitioner


MTM application in product and process planning


MTM Planning Concept3-Phase Model

Target: Design optimization with earliest possible quantification

DesignDesign PlanningPlanning Production

PROKONPROKON

Planning AnalysisPlanning Analysis

Efficiency AnalysisEfficiency Analysis

- assembly friendliness- process reliability- quality target

- organization- work design- methods

- fine tuning- instruction- kick off


PROKONis the MTM tool for supporting product design

Assembly

value-addingactivities

non value-addingactivities

waste

positionscrew

engageglue

distanceswaste disposalreading order

transporting material

adjustmentrework

categories analyzed by PROKON


Concept Design Procurement Pre-series Prod. Start

ProKon

Planning analysisPerformance analysis

Cost calculation

Milestones overview (an example)Acquisition

1

3 46

7

2

5

procurement and installation equipment

CIP

1 23 4 5 6 7

SOP


n ProKon matrix (actual)n Actions for design

optimizationn ProKon matrix (target)

n Conducting 1st ProKon workshop

n Analysis of producibilityand design for assembly

Start ProKon

n Process structure (MTM data)

n Detailing of the methods of production and production processes on the basis of MTM

n Development of alternative solutions

n Bill of material, material where-used

n quantities and customer‘s takt time

n First results of ProKon-Workshop

n Make or Buy decisionn Production process defined

Startplanning-analysis

n updated ProKon-matrix on the basis of feasible actions

n Updated ProKon-matrix for detailed design as default specification

n Updating with ProKon-Workshop

n Continue updating results from milestone 1

n Feedback on action feasibility (customer, process engineers)

n implementing the planned design-potentials in design-phase

n 2nd workshop at the end of concept- or at the beginning of design-phase

ProKon

verificationcontentrequirementsMile-stone

ProK

on

1

2

3plan

ning

-an

alys

is

Milestones overview (1/3)


n All working methods and processes are analyzed

n Line balancing is defined n Layout is definedn Equipment specs are

released for the suppliers

n MTM-Expert approves planning analyses for procurement, checks on the basis of requirements and verification

n Customer feedback on implementation

n Actions from updated ProKon-Workshops (milestone 2)

n Alternative processes are created and assessed, process is selected

n No estimated times in processes à 100 % MTM analyses

n All process-times are defined

n Line balancing scenarios are developed

n Takt time is defined

Permission procure-

mentin

planning-analysis

n Current planning-analyses are fine tuned based on field observations

n MTM-Expert releases planning analyses in order to manage daily efficiency

n Equipment is installedn Modifications are updated in

the MTM planning analyses

Efficiencyanalysis

verificationcontentrequirementsmile-stone

Plan

ning

ana

lysi

s 4

5



n Calculation sheetsn Calculation of production costs at each planning level on basis of MTM-elements

n results at each milestone ProKon, Planning- and efficiency-analysis are available

n Feedback of customer

n Efficiency-analysis on basis of MTM

n Current line balancingn Work instructions are

available

n MTM-Expert approves efficiency-analysis

n Transfer into routing

n Methods of production and operations are analyzed in detail, every variable is defined

n Implementing further design potentials

n Employees are trained in production method

n Line balancing is matchedn Approval of work counciln Recording process times

OK for Efficiency analysis for SOP

n Audit questionnairen Check of the relevant data from performance analysis

n Check of work station layout

n Trigger for Continuous Improvement (CIP)

n A half year after SOPn Steady state

Validation audit

verificationcontentrequirementsmile-stone

6

7

Effic

ienc

y an

alys

is

updating at each

milestone

1 6to

calc

ulat

ion



MTM and Ergonomics


Synergies between MTM and Ergonomics

l As modern industrial engineers we have a huge responsibility when designing and optimizing technological systemsl We cannot afford to separate process

efficiency from ergonomics: it would be too expensivel Synergies result in the cost of ergo analysis

representing only a small percentage with respect to the resources required to take care of professional diseases caused by biomechanical overload (absenteeism, low performance, social costs, etc.)


IMD initiatives

l Official MTM techniques and most accepted ergonomic analysis systems have been integrated into an innovative scientific approach to work study¡ It puts human needs and capabilities at the

forefront¡ It focuses on the process design phase (and

product design will come next)¡ It overcomes the paradigm “High Productivity –

High human stress”


development phase

Opportunities of change

0 1 3 42

Method design and ergonomic risk assessment at the earliest stage of dev’t

Cost of change


IMD Target

lThe MTM-ERGO tool must meet the following requirements:¡ Additional cost for adding ergo codes < 25%¡ Utilize official MTM systems¡ Utilize recognized ergonomic analysis systems¡ Utilized by industrial engineers


2 different levels of ambition

MTM time elementsMTM time elements

1. Risk detection

2. Risk evaluationErgonomic

analysis systems(niosh, ocra, owas, etc.)

ERGO codesERGO codes

Evaluation tool(e.g. EAWS)

SW support

posture predictor


European Assembly Work-Sheet (EAWSEAWS)

Ergonomic risk screening tool


EAWS is a 1° level system for screening ergonomic risk due to biomechanical

overload.

What is EAWS

Note 1st LEVEL systems: risk evaluation systems which require a quick screening checklist.

2nd LEVEL systems: risk evaluation systems which require a detailed analysis with index calculations. They are applied where a possible risk has been already detected by a 1st level system.


New EAWS approach to risk assessment

ergonomic risk analysis according to EAWS

ergonomic risk assessment according to CEN / ISO

classical stress - strain concept

Strain

Risk evaluationaccording to

traffic light scheme

Risk evaluationaccording to

traffic light scheme

Limit value

Stressorssimultaneous /

consecutivetask / environment

Individualcharacteristics, abilities

and skills

Complex load situation e.g.

manual material handling

Relevant characteristics of the intended user population

Complex loadsituations in various stress situations (e.g.

manual material handling and action forces)

Relevantcharacteristics

of the intended

user population

Sum ofrisk scores

for all modes ofstressors

per time unit


Analyzing systems for biomechanical load

area of risk CEN ISO 2° level

Whole body postures 1005-4 11226 OWAS

Action forces 1005-3 11228-2 RULA

Manual material handling 1005-2 11228-1 - NIOSH- SNOOK-CIRIELLO

Upper limb loadin repetitive tasks 1005-5 11228-3

OCRASTRAIN INDEXHAL-TV

Norms Analyzing systems

AAW

S

EAW

S

1° level


CEN & ISO ergonomic standards

standard CEN standard ISO

EN ISO 14738 Safety of Machinery - Anthropometric requirements for the design of workstations at machinery

EN 1005 - 2 Safety of Machinery -Manual handling of machinery and component parts of machinery

EN 1005 - 3 Safety of Machinery -Recommended force limitsfor machinery operation

EN 1005 - 4 Safety of Machinery -Evaluation of working postures in relation to machinery

EN ISO 7250 Basic human body measurements for technological design

ISO 11226 Ergonomics -Evaluation of working postures

ISO 11228 - 1 Ergonomics - Manual handling - Lifting and Carrying

ISO/DIS 11228 - 2 Ergonomics - Manual handling - Pushing and pulling

EN 1005 - 5 Safety of Machinery -Manual handling of low loads at high frequencies

ISO/CD 11228 - 3 Ergonomics - Manual handling - low loads at high frequencies


ENEN 10051005--22EN 1005EN 1005--33

Action frequency

Forces/loads

ISOISO 1122811228--11ISO 11228ISO 11228--22

ISO 11228-3Development phase

Production

Design

Posture prediction

Tc < 30 sec.

Tc > 30 sec.

EN 1005-5

30 N

Application fields


Development phase[time]

Opportunities of change CostsCosts

aumento[%]

Design Planning Production

Preventive Ergonomy

Measurement

Risk analysis

Redesign

Simulation


Project Manager(Ing. G. Caragnano)

Project Sponsors(IMD, MTM, IAD, UNI.TO,

EPM)

• Goal setting• Define project scope• Assign resources

Project Team• Prof. C. Romano (UNI.TO)• Dr. A. Baracco (UNI.TO)• Prof. Bruder (IAD)• Dr. Ing. K. Scaub (IAD)• Ing. I. Lavatelli (APEX)

Software development• K. Ebert (MTM)

Field Application Group

FIAT Whirlp IVECO Porsche VW

Reference Groups• National MTM Assoc.• IEA federated members• Employers federations• Unions

Project owner(MTM)

• Project objectives• Timing• Resources

Project OrganizationLegendaIMD International MTM DirectorateIAD Technical University of DarmstadtUNI.TO Univ ersity of TurinEPM Ergonomia della Postura e del Mov imento (Milan)MTM International MTM Group f or Productivity ServicesIEA International Ergonomics AssociationPM Project Manager

Smart


Field Application Group

l This group is formed by companies willing to test the new tool on the field (3 days). The field tests will be carried out by MTM consultants

l Field Test Group members have the opportunity to follow the development process through direct attendance to project meetings and reporting

l Field Test Group members will participate to the first training session

l The participation fee is 5.000 € per company (invoiced by the IMD) (http://www.mtm-international.org)


MTM Logistics

MTM applied to logistic processes


MTM LOGISTICSlObjectives¡Share a fact-based concept tol size logistic workforcel monitor logistic efficiency and support continuous

improvementl carry on What-if analyses for alternative layout

solutions¡ Develop and implement a standard Plan For

Every Part (PFEP) database


STEPS AND PHASES

PROJECT MANAGER

MTM CONSULTANT(S)

CUSTOMER LOGISTIC EXPERT

OTHER CUSTOMER RESOURCES

Phase1:ProjectSetup Phase2:

DataRetrieving

Phase3: System Settings

Phase4:PFEP

Phase5:MTM Analysis

Phase6:Logistic

BehaviourCaractheri-

zationPhase7:

Calculation

Phase8:Setup of

Logistic DataSystem for

ActiveMonitoring

of Efficiency

CHECK CHECK

Project Team

Phase1

Phase2

Phase3

Phase4

Phase5

Phase6

Phase7

Phase8

Layout, Material Flow, Logistic Transactions & LocationsMeans of transport, Container, extract BOM from ERP, Refine Logistic Locations

Distance Matrix, Curves Matrix, Get & PlaceMapping Process

Extract data from PFEP

With TiCon, develop MTM-Logistics Analyses

Logistic characterization of components (designs)

Calculation of logistic process costs

Set up logistic efficiency monitoring system

STEPS SET UP ANALISYS CONSOLIDATION

PROJECT MANAGER

MTM CONSULTANT(S)

CUSTOMER LOGISTIC EXPERT

OTHER CUSTOMER RESOURCES

Phase1:ProjectSetup Phase2:

DataRetrieving

Phase3: System Settings

Phase4:PFEP

Phase5:MTM Analysis

Phase6:Logistic

BehaviourCaractheri-

zationPhase7:

Calculation

Phase8:Setup of

Logistic DataSystem for

ActiveMonitoring

of Efficiency

CHECK CHECK

Project Team

Phase1

Phase2

Phase3

Phase4

Phase5

Phase6

Phase7

Phase8

Layout, Material Flow, Logistic Transactions & LocationsMeans of transport, Container, extract BOM from ERP, Refine Logistic Locations

Distance Matrix, Curves Matrix, Get & PlaceMapping Process

Extract data from PFEP

With TiCon, develop MTM-Logistics Analyses

Logistic characterization of components (designs)

Calculation of logistic process costs

Set up logistic efficiency monitoring system

STEPS SET UP ANALISYS CONSOLIDATION


PROJECT SCOPE

l Incoming: from receivingdocks to warehouses

l Providing: fromwarehouses/sub-assy tolines / sub-assy

l Internal warehousing: from lines/sub-assy tobuffer zones

l Outgoing: from end of lines / sub-assy to truck or empty containers totruck

All logistic processes door-to-door in a factory


INFORMATION FLOW

Logistic LocationsDistances, Curves

Map Handling ProcessesMap Logistic Activities

MTM Logistics Analysis

Efficiency Analysis

Traditional PFEP(Plan For Every Part)

Cost per Area(Assembly, CDC, etc.)

“What if” analysis(support process improvement)

INPUT LAYOUT FLOWS MANNINGVOLUMESBOM + CONTAINER LIST

SET UP

Cost perProcess

ANALYSISFGA Standard PFEP

(with log. timesper component)

CONSOLIDATION Cost per Resource(eg. Forklift ProvidingLine #1, UTE #4)

Analytical Job Assignmentper resource

Logistic LocationsDistances, Curves

Map Handling ProcessesMap Logistic Activities

MTM Logistics Analysis

Efficiency Analysis

Traditional PFEP(Plan For Every Part)

Cost per Area(Assembly, CDC, etc.)

“What if” analysis(support process improvement)

INPUT LAYOUT FLOWS MANNINGVOLUMESBOM + CONTAINER LIST

SET UP

Cost perProcess

ANALYSISFGA Standard PFEP

(with log. timesper component)

CONSOLIDATION Cost per Resource(eg. Forklift ProvidingLine #1, UTE #4)

Analytical Job Assignmentper resource


INTERNATIONALLY ACCEPTED MTM LOGISTIC DATA FOR MEASURING PROCESSES

Code With Without With Without With WithoutGet 7LT FM FO SM SO GM GO

SAAA 833 603 983 718 969 644SAAB 980 750 1167 902 1326 1001SAAC 1141 911 1368 1103 1767 1442SAAD 1326 1096 1600 1335 2275 1950SABA 934 854 1084 1123 1208 1103SABB 1081 1268 1555SABC 1242 1469 1996SABD 1427 1701 2504SACA 1078 998 1228 1158 1510 1405SACB 1226 1413 1857SACC 1386 1613 2298SACD 1572 1845 2807SADA 1245 1165 1395 1325 1859 1754SADB 1392 1579 2206SADC 1553 1780 2647SADD 1738 2012 3156

With or without 90° orientation

Place

Forklift truck

Lift fork truck with

retractable mast

Pedestrian-controlled pallet truck

Measurement unit: TMU

to 4,0 m height

on the ground

on the groundto 1,2 m heightto 2,5 m heightto 4,0 m height

to 1,2 m height

to 1,2 m heightto 2,5 m heightto 4,0 m height

Fork truck

on the ground

to 2,5 m height

on the groundto 1,2 m heightto 2,5 m height

to 4,0 m height

From the ground

From 1,20 m height

From 2,50 m height

From 4,0 m height


MTM Office System (MOS)

Admin Process Improvement


Administration Efficiency

Increasing economic importance for administration activities

• continuously growing importance of the administration sector• gain of efficiency in service processes by standardization

the competitive advantage in the administration is measured through their efficiency

-to measure the efficiency a norm is required

MMTM TM –– OOffice ffice –– SSystemystem


Components

MOS is based on a selection of various systems to process the analyses in different levels of detail

Thus reproducible data blocks are combined into operation sequences to facilitate the analysis

Some examples .............. à


MTM Office SystemHandle - Basic Data

210HIper sheet or set, with open or close, without folding upInsert or Remove / envelope75HHper sheet or set (also folder without mechanism)Insert or Remove / sheet

190HGrocker lever, ring binder, folderOpen / Close mechanism

100HF

tap

fold

punch

cut

connect

take apart

Work

200HEapply adhesive labelLabel

60HDstamp

underline

Mark

85HC2 sheets combine, 1 sheet allocate

count per 10 units, sort per sign and sheetCombine/Sort

60HBget and place e.g. pen, stamp or similar and put awayHandle tools

40HAe.g. turn page, tear off sheet, open or close,

get or put away

Get and Place objects

TMUMOS-XXxExplanationsHandle


MTM Office SystemMental functions - Basic Data

70MA1register, text section known rangesimpleSearch for and Find

170MA2specific page, text section unknown rangedifficult

10MB1word

signRead number per 3 digits, character per 3

letters70MB2per begun line A4line

20MC1word

signCheck number per 3 digits, character per 3

letters140MC2per begun line A4line

40MD1word

signCompare number per 3 digits, character per 3

letters300MD2per begun line A4line

25ME1digit, letter, charactersymbolWrite - hand 150ME2including transferword

800ME3per begun line A4, including transferline

TMU

MOS-XXxExplanationsMental functions


75SC2search and find position and click

posit. sing.-stage

240SC3search directoryposit. multi-stage

40SC4select pull-down menumask170SC5graduallyscroll

55SC1orientate on screenbasic value

Select

20SBposition and clickOperate mouse10SApress single keyOperate keyboard

380SDformat selected text, several lines

formatEdit

TMUMOS-XXxExplanationsScreen actions

MTM Office SystemScreen actions - Basic Data


Analysisadditional, support and

ancillary activities

Classification process steps

Analysismain manual

activities

• ABC-Analysis• process modelling

• MTM-components

• self recording• multi-moment analysis• interviews

From Process to Method Approach

ma

in p

roce

ss

ma

in p

roce

ss

ma

in p

roce

ss

ma

in p

roce

ss


WEB Site

www.mtm-international.org


IMD WEB site: www.mtm-international.org

Imd Presentation Dec 2008.V01

Business

Transcript of Imd Presentation Dec 2008.V01