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Methods-time measurement

Methods-Time Measurement (MTM) is a predetermined motion time system (PMTS) used in industrial engineering 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.^[1]^[2] Developed in 1948 by Harold B. Maynard, G.J. Stegemerten, and John L. Schwab, MTM builds on earlier motion study principles pioneered by Frank Bunker Gilbreth, focusing on optimizing workplace methods to reduce unnecessary movements and improve efficiency.^[1]^[3] 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.^[4] 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), grasp (securing an object), position (locating or aligning an object), release (relinquishing control), and eye times (visual focus and travel).^[1]^[3] 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.^[3]^[2] 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.^[5] MTM's applications span manufacturing, logistics, and service industries, where it supports work standardization, productivity enhancement, bottleneck identification, and ergonomic improvements by providing objective data for process design and labor planning.^[2]^[6] Globally recognized through organizations like the International MTM Association, it remains a foundational tool for digitizing work standards and fostering competitive efficiency in human-centered production.^[1]

Overview

Definition and Purpose

Methods-Time Measurement (MTM) is a predetermined motion time system (PMTS) used in industrial engineering 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 stopwatch timing.^[1]^[7] 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.^[8] The core purpose of MTM is to facilitate method improvement and optimization in industrial settings by enabling engineers to design and refine work processes proactively, estimate cycle times for novel tasks, support accurate cost analysis, and incorporate ergonomic principles to minimize physical strain before tasks are implemented in production.^[1]^[9] By focusing on the sequence and quality of motions, MTM helps organizations achieve higher productivity, reduce waste, and standardize operations across diverse manufacturing and assembly environments.^[7] 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.^[1]^[8] This proactive orientation allows for the elimination of inefficiencies at the design stage, making MTM particularly valuable for planning new workflows. MTM traces its origins to early 20th-century motion studies in industrial engineering.^[1]

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 analysis. 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 prediction and improvement of task efficiency without relying on direct observation of actual performance.^[10]^[3] 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.^[10]^[9] MTM analysis assumes a standard operator—an average skilled worker performing under normal environmental and physiological conditions—to establish consistent baselines for motion times. This standardization avoids variability from individual differences, focusing instead on the inherent efficiency of the motions themselves rather than operator-specific factors. Allowances for fatigue, 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 standard time, 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.^[10]^[11]

History

Origins and Development

The origins of Methods-Time Measurement (MTM) trace back to the principles of scientific management pioneered in the early 20th century. Frederick Winslow Taylor's time studies, initiated in the 1880s and formalized in his 1911 publication The Principles of Scientific Management, emphasized measuring worker performance to establish efficiency standards in industrial settings.^[12] 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.^[13] 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 Westinghouse Electric Corporation 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.^[14] 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 predetermined motion time system, assigning time values in time measurement units (TMUs) to basic motions based on empirical data from average-skilled workers.^[15] The book marked MTM's transition from experimental research to a practical tool for industrial engineering, enabling precise method evaluation without on-site observation.^[16] Following 1948, MTM evolved rapidly to accommodate varying analysis needs. By the 1950s, the U.S. MTM Association for Standards and Research was established to promote and refine the system, while international adoption spurred further variants.^[16] In the 1960s, MTM-2 emerged as a less detailed variant for broader applications, officially recognized by the International MTM Federation in 1965, expanding MTM's utility across detail levels from fine manual operations to general assembly tasks.^[17] This proliferation solidified MTM as a global standard for work measurement.

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.^[18] Maynard, along with his collaborators, developed MTM through a consultancy assignment sponsored by the Westinghouse Electric Corporation, focusing on analyzing and standardizing manual work methods to improve industrial efficiency.^[19] 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.^[20] 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.^[16] 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.^[21] Stegemerten contributed to validating the time values assigned to these motions through empirical studies, ensuring the system's empirical reliability.^[22] 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.^[20] 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.^[23] 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 Germany, Switzerland, and Austria, to adapt the system for diverse production contexts such as batch manufacturing.^[24]

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 human body 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.^[25]^[24]^[26] 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; Grasp (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, wrist, forearm, or body; and Apply Pressure (AP), exerting controlled force to fasten or manipulate.^[25]^[24] 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 visibility, precision needs, and clearance tolerances, with distance measured along the path from the hand's starting position. Grasp and Position consider object size, 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.^[25]^[27] 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 bending, 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.^[24]^[27] In sequence analysis, 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.^[28]^[25]

Time Assignment and Calculation

In Methods-Time Measurement (MTM), predetermined times are derived from empirical tables established through laboratory studies of skilled operators performing basic motions under controlled conditions, using high-speed motion pictures to capture and analyze movements at a performance level of 100% on the level of manual skills (LMS).^[15] 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.^[25] 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.^[7] 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:

\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, fatigue, and minor delays, typically at 15% of the normal time for sedentary or light work, resulting in the standard time.^[29] 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 standard time of 0.90 seconds.^[25]

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 electronics assembly, enabling precise task allocation and workflow 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 electronics manufacturing, MTM systems analyze work cell processes to predict accurate times for repetitive operations, supporting overall production planning and cost estimation.^[30]^[31] Beyond manufacturing, MTM finds applications in healthcare for standardizing procedures, such as evaluating the usability of medical devices to minimize operational errors and enhance patient safety.^[32] In logistics, particularly warehouse operations, MTM-Logistics is employed to optimize picking and packing processes, establishing standard times that improve order fulfillment efficiency in third-party logistics environments.^[33] In the service sector, MTM supports task design in administrative and service activities, such as filing and data entry, where it breaks down manual operations to streamline processes and reduce variability.^[24] MTM integrates seamlessly into broader process improvement frameworks, including lean manufacturing, where it complements value stream mapping to eliminate waste and shorten lead times. It also aids ergonomics assessments by quantifying motion patterns to mitigate repetitive strain injuries, providing engineers with data-driven insights for healthier workstation designs. A case study in manufacturing assembly lines demonstrated MTM's impact, where combining MTM-UAS with simulation modeling rebalanced tasks across workstations, increasing output by 11.4% per shift while reducing cycle time disparities.^[34]^[17]^[35] 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.^[36]^[1]

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.^[37] Stopwatches are commonly employed for validation, comparing predetermined MTM times against observed performance to ensure accuracy in real-world applications. Video analysis tools support motion capture by recording and replaying operations, allowing analysts to dissect movements frame-by-frame for precise MTM coding and ergonomic assessment.^[38] Dedicated MTM software, such as TiCon developed by MTM SOLUTIONS GmbH, automates TMU calculations using MTM building block systems and integrates 3D ergonomics for workplace evaluation, enabling digital process planning and benchmarking.^[39] MTM-compatible simulation programs like Simio facilitate virtual task modeling by incorporating MTM standards to optimize assembly lines and predict performance metrics.^[35] These tools streamline analysis 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 analysis through automated code extraction and guided verification, reducing manual effort.^[40] Mobile apps, exemplified by TMU Calculator, enable on-site MTM analysis via tablet interfaces, supporting multiple MTM systems and direct data export for field-based efficiency.^[41] Overall, these tools and software significantly speed up MTM analysis, often reducing processing time from hours to minutes while allowing exports to enterprise resource planning (ERP) systems like SAP for real-time standard setting and integration.^[42]

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 fatigue or observer interpretation.^[43] This results in consistent standards that can be applied uniformly across different shifts, locations, and operators, ensuring reliability in performance evaluation and reducing disputes over time norms.^[44] 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.^[44] 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.^[45] 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 manufacturing and assembly.^[44] It supports employee training programs by providing clear, standardized instructions and underpins incentive systems through precise time benchmarks, while delivering quantifiable returns on investment; case studies demonstrate productivity gains, such as a 28% reduction in throughput time in an assembly process, enabling higher output without additional resources.^[45] 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 injury rates, such as repetitive strain injuries, by optimizing workstation layouts and movement patterns.^[45] This not only enhances worker well-being but also contributes to sustained productivity by minimizing downtime due to health issues.^[44]

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 stopwatch time studies for simpler operations.^[44] 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.^[44] This extended analysis time reduces its practicality for quick assessments, as preparing standard data charts demands substantial effort that may offset anticipated savings.^[21] Recent advancements, including Industry 4.0 technologies like AI-assisted motion detection and virtual reality transcription (as of August 2025), have begun to mitigate these time barriers by automating parts of the analysis process.^[46] 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).^[47]^[48] Analysts require extensive skill development, experience, and judgment to apply the system effectively, often necessitating ongoing certification maintenance.^[21] These demands create barriers, particularly for smaller operations lacking dedicated resources for such investments.^[44] 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 fatigue and skill levels, leading to discrepancies when validated against actual chronometer observations.^[44] Elemental time values across MTM variants can vary by more than ±5%, highlighting inconsistencies in handling operator-specific variances.^[21] Consequently, MTM proves less reliable for non-repetitive or creative tasks, where motion patterns are irregular and complex, making detailed breakdowns impractical.^[44] 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.^[44] Additionally, the system's data tables, derived from mid-20th-century studies, often fail to reflect modern tools, automation, or workplace changes, resulting in outdated time estimates.^[21] 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 Brazil where it remains underutilized despite potential benefits.^[44] 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 ergonomics that original tables overlook.^[49] These revisions aim to incorporate force and posture considerations but require further validation to maintain MTM's relevance.^[17]

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Methods time measurement on the optimization of a productive ...
Dec 16, 2020 · Methods time measurement on the optimization of a productive process: A case study ; improved skills regarding the implementation of production.
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[PDF] 2025 IISE Course Overview
Course Page. Methods Time Measurement (MTM-1 ). 7.0. ✓. $4,565/$4,195. Course Page. MODAPTS Certification. 2.1. ✓. ✓. ✓. $1,625/$1,255. Course Page. Staffing ...
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(PDF) Modified method time measurements for ergonomic planning ...
Aug 6, 2025 · Therefore, it is concluded that the application of the MTM provided gains in productivity and in the quality of the service provided, as ...