Lean and MTM – scientific, practical and educational perspectives to enhance productivity
The Method Determines the Success Pole position in international competition through the consistent use of MTM across the process of product emergence.
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 1
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Prof. Dr. Peter Kuhlang, Head of MTM-Institute, German MTM-Association
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 2
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Agenda
1. Introduction Who we are
2. Lean thinking and MTM The mutual context and “their” relationship
3. Lean and MTM application examples Lean Production: Assembly of micro contactors
Lean Logistics: Packing of spare parts
4. Preconditions and necessities to apply MTM Software and international standardised training programmes
5. Outlook MTM Productivity Management concept – Industrial Engineering Handbook
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM-Organization
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 3
German MTM-Association
German MTM-Company
MTM do Brasil Sao Paulo
MTM Polska Wrocław
MTM PSC USA Chicago
MTM China Shanghai
MTM India Chennai
Academy Berlin, Stuttgart
Institute Berlin, Zeuthen
Association Hamburg
Software Dresden
Training Center Stuttgart
Engineering Services Hamburg, Stuttgart
Consulting Stuttgart
Companies Abroad
non-p
rofit
pro
fit
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 4
Overview about MTM
MTM Methods-Time Measurement
Instrumental: methodology
Avoiding waste in value stream
Information stream
Material stream
Value added
Construction Planning Production
Organizational development
Organizational planning
Organizational sequence
Institutional: organization
Non-profit associations / for profit consultancy
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Lean-Toolbox
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 5
SMED
More tools: • Gemba • Poka-Yoke • DfMA • Kata • Andon • Cardboard Eng. • …
Structured in production systems • WCM • TPS • …
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Return to Work Measurement – Shigeyasu Sakamoto
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 6
• Companies have to think about smart
working methods rather than the trendy (sometimes impractical ways) methods
• Secret of productivity improvement:
engineered standard time and labor performance control system
• IE´s must follow a balance between
maintaining a commitment to the basic traditional tools and rolling with the evolution
• For real productivity improvement it is
sometimes better to return to traditional measurements instead of modern methods like Kaizen or Lean Management
• But there is no right or wrong way to improve
the productivity
Source: Industrial Engineer, member forum, Mar 2009; 41, 3; Docstoc pg. 24
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 7
Lean Thinking and MTM
Applying Lean methods to identify and eliminate waste
Productivity
time (years) SOP
Waste and non-value adding
tasks
Added value
Work content
Waste and non-value adding
tasks
Added value
Added value
identify and eliminate
waste
Source: Miller/Blockhus, 2005
?
Applying more, new, different Lean methods or/and approaches in broader scope Lean Logistics, Lean Layout Lean Engineering, Lean Administration Short-cyclic improvement process - Kata
Intensify the understanding of
processes/value streams view into work systems time determination
MTM acts like a scale and
defines productivity level
2
1
Waste andnon-value adding
tasks
Addedvalue
Waste andnon-value adding
tasks
Addedvalue
Addedvalue
identify andeliminate
waste
How to counteract the diminishing productivity progress?
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 8
Time vs. method focus
• Modeling of human work
• Plan and explore the optimal human operating point
• MTM provides a norm performance
Work contet (time)
Combination: Increase of intensity
and improvement of
processes
• Systematic modelling of processes based on process blocks
• Develop and apply standard processes
Restrictions
Current processes
Focus : time
Lean/CIP
Ideal Target processes
Focus: (work) method
Systematic planning
t
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 9
How to apply the MTM methodology
Start: Assemble connection plug to compressor and tighten it to torque.
MTM-Datacard (exc. of MTM-UAS Basic Operations)
Distance (cm)
0 ≤ 20 20 ≤ 50 50 ≤ 80
… … … …
Get and Place AF1 (40 TMU)
AF2 (65 TMU)
AF3 (80 TMU)
… … … …
Handle Aid HB1 (40 TMU)
HB2 (60 TMU)
HB3 (75 TMU)
… … … …
Plan or observe operation
Finish:
Modelled standard operation incl. standard time (285 TMU ≈ 10s)
Plug to thread AF2 1 65 65 1 Turn on ZA2 5 15 75 2
Torque wrench HB2 1 60 60 3 1. Turn ZA1 1 5 5 4
2.-3. Turn ZC1 2 30 60 5
Σ 285
Turn to torque ZD 1 20 20 6
Choose process blocs and model operation
x
Assemble connection plug
D Z 7 0 5 . 0 5 . . . 5
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 10
MTM application the whole value streams
Production planning
PPCDayly order
daily
Customer
Assembly plantCologne
18.400 Pcs./month12.000 left6.400 right
20 Pcs./container
2 shifts
CT: 40s
ST: 0
Reliability: 100%
Assembly II
1200 le640 ri
2d
40s
Workers: 1
SC: 2
Shipping
2700 le1440 ri
4,5T4,5d 23,6d
188s
CT: 62s
ST: 0
Reliability: 100%
Assembly I
1600 le850 ri
2,7d
62s
Workers: 1
SC: 2
CT: 46s
ST: 10min
Reliability: 80%
Spot welding II
1100 le600 ri
1,8d
46s
Workers: 1
SC: 2
CT: 39s
ST: 10min
Reliability: 100%
Spot welding I
4600 le2400 ri
7,6d
39s
Workers: 1
SC: 2
CT: 1s
ST: 1h
Reliability: 85%
Die cutting
Steel coils5 days
5d
1s
Workers: 1
EPEI: 2 weeks
Supplier
Ruhr AG
90/60/30-day-forecast
Tuesdayand
thursday
Weekly order
6-Weeks-forecast
Weekly planning
Daily planning
Flow of material & information
Flow of information
Incoming goods
Work method
Balancing
Multiple workers and workplaces
Setup times
Intra-plant transport
Shipping/ Packing/ Dispatching
Operating times Added value
Ergonomic work system design
Informational work
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 11
Software support in productivity management
MTMmobile for iPad
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 12
MTM educational concept (Germany)
Internat. standardised educational levels: • MTM-Practitioner • MTM-Instructor
Education programs for students: Basic-MTM (MTM-1 and UAS)
MTM-Practitioner
Prozessarchitecture
Value Stream Mapping / Logistics
Busines Process Management
Design for Assembly: ProKon
Productivity Management
Lean Line Design
MTM-Engineer
3 d
33 d
3 + 2 d
2 d
3 d
5 d
3 d
Total: 54 d
MTM-1 (part 1)
MTM-SD MTM-UAS MTM-MEK
MTM-Practitioner-Semianr
or or
MTM-Practitioner-Diploma
MTM-2 or á 5 d
MTM-Practit.-Homework/Thesis
5 d
Duration of training: 33 d
EAWS
5 d
8 d
MTM-1(part 2)
or
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
COD. COURSE TITLEUnit of
measure
Min
Dura
tion
Recom
mended D
ura
tion
MT
M-1
MT
M-2
SA
M
MT
M-U
AS
MT
M-M
EK
EA
WS
PR
OK
ON
MT
M T
RA
INE
R
EA
WS
TR
AIN
ER
MT
M I
NS
TR
UC
TO
R
EX
AM
+ C
ER
TIF
ICA
TIO
N
TE
ST
IMO
NIA
L C
ER
TIF
ICA
TE
BLU
E C
AR
D
GR
EE
N C
AR
D
GROUND COURSES
G01 INTRODUCTION TO WORK ANALYSIS days 2 3 X
G02 MTM BASE (1) days 3 3 X
CERTIFICATE LEVEL - FUNDAMENTAL SPECIALISTIC COURSES
F01 MTM-1 days 10 15 X
F02 MTM-2 days 5 5 X
F04 SAM days 5 5 X
F05 MTM-UAS days 5 5 X
F06 MTM-MEK days 4 5 X
F07 EAWS days 5 8 X
F08 PROKON days 2 3 X
MTM-PRACTITIONER LEVEL
P01 SHOP FLOOR TUTORSHIP (per technique) days 5 10
P02 EVIDENCE OF COMPETENCE IN PRACTICAL APPLICATION evaluation - X
MTM-INSTRUCTOR LEVEL
I01 INSTRUCTOR COURSE days 3 5 X
I02 PROJECT EXPERIENCE months 6 36
I03 TEACHING EXPERIENCE course - 1 X
I04 PROJECT WORK PRESENTATION days 1 1 X
IEX EXAMINATION days 1 1 X X
MANDATORY
RECOMMENDED
Recognized Qualification:
1 c
ho
ice
LICENSECERTIFINSTRUCTOR
1 c
ho
ice
PRACTITIONER
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 13
International standardised educational levels
Source: IMD, Code of Practice, 2014
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Global footprint of MTM
MTM a reliable measure in science, practice & training
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 14
The work from men‘s perspective.
The process, or rather the optimal method determines the time.
There are limits (e.g. utilization) but this transparency is necessary.
A fair measure of performance Work at an optimal level.
Work smarter, not harder!
Trust Responsibility Fairness
Sense
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Understanding MTM: Industrial Engineering Handbook
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 15
Productivity
SOP
?
2
1
COD. COURSE TITLEUnit of
measure
Min
Dura
tion
Recom
mended D
ura
tion
MT
M-1
MT
M-2
SA
M
MT
M-U
AS
MT
M-M
EK
EA
WS
PR
OK
ON
MT
M T
RA
INE
R
EA
WS
TR
AIN
ER
MT
M I
NS
TR
UC
TO
R
EX
AM
+ C
ER
TIF
ICA
TIO
N
TE
ST
IMO
NIA
L C
ER
TIF
ICA
TE
BLU
E C
AR
D
GR
EE
N C
AR
D
GROUND COURSES
G01 INTRODUCTION TO WORK ANALYSIS days 2 3 X
G02 MTM BASE (1) days 3 3 X
CERTIFICATE LEVEL - FUNDAMENTAL SPECIALISTIC COURSES
F01 MTM-1 days 10 15 X
F02 MTM-2 days 5 5 X
F04 SAM days 5 5 X
F05 MTM-UAS days 5 5 X
F06 MTM-MEK days 4 5 X
F07 EAWS days 5 8 X
F08 PROKON days 2 3 X
MTM-PRACTITIONER LEVEL
P01 SHOP FLOOR TUTORSHIP (per technique) days 5 10
P02 EVIDENCE OF COMPETENCE IN PRACTICAL APPLICATION evaluation - X
MTM-INSTRUCTOR LEVEL
I01 INSTRUCTOR COURSE days 3 5 X
I02 PROJECT EXPERIENCE months 6 36
I03 TEACHING EXPERIENCE course - 1 X
I04 PROJECT WORK PRESENTATION days 1 1 X
IEX EXAMINATION days 1 1 X X
MANDATORY
RECOMMENDED
Recognized Qualification:
1 c
ho
ice
LICENSECERTIFINSTRUCTOR
1 c
ho
ice
PRACTITIONERProduction planning
PPCDayly order
daily
Customer
Assembly plantCologne
18.400 Pcs./month12.000 left6.400 right
20 Pcs./container
2 shifts
CT: 40s
ST: 0
Reliability: 100%
Assembly II
1200 le640 ri
2d
40s
Workers: 1
SC: 2
Shipping
2700 le1440 ri
4,5T4,5d 23,6d
188s
CT: 62s
ST: 0
Reliability: 100%
Assembly I
1600 le850 ri
2,7d
62s
Workers: 1
SC: 2
CT: 46s
ST: 10min
Reliability: 80%
Spot welding II
1100 le600 ri
1,8d
46s
Workers: 1
SC: 2
CT: 39s
ST: 10min
Reliability: 100%
Spot welding I
4600 le2400 ri
7,6d
39s
Workers: 1
SC: 2
CT: 1s
ST: 1h
Reliability: 85%
Die cutting
Steel coils5 days
5d
1s
Workers: 1
EPEI: 2 weeks
Supplier
Ruhr AG
90/60/30-day-forecast
Tuesdayand
thursday
Weekly order
6-Weeks-forecast
Weekly planning
Daily planning
Flow of material & information
Flow of information
Incoming goods
Work method
Balancing
Multiple workersand workplaces
Setup times
Intra-plant transport
Shipping/ Packing/Dispatching
Operating times Added value
Ergonomic worksystem design
Informational work
Productivity Management by MTM
Preven
tio
n
Su
sta
inab
ilit
y
Design evaluation(Value analysis, QFD)
Assembly oriented productdesign (ProKon)
Technical calculation
Supply and actualise bill of activities/work plan with target times
Task analysis and synthesis, task relevance analysis
Process analysis and documentation (Flow charts, table visualisation)
Process modelling and improv. with MTM process building block systems
Supplementary techniques (estimate, standard data, process time eval)
Layout planning
Ergonomic Assessment
Planning and implementing ofwork systems
Ramp-up & shop floor management
Supplementary techniques(self-recording, time measurment, work sampling,…)
Target time analysis and synthesis (target and lead times)
Value Stream Mapping
Company-specific building block systems / target time management
Personnel requirement planning and controlling
Improvement management
(labor) time management
Renumeration differentiation
Project management
1.Product development 2.Process development 3.Operation & improvement
Source: Bokranz/Landau, 2012
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 16
Industrial Engineering - Can you imagine it?
If it moves, it’s Mechanical.
If it doesn’t, it’s Civil.
If it smells, it’s Chemical.
If it is invisible, it’s Electrical.
And if you can’t even imagine it,
it’s INDUSTRIAL! [Oren]
MTM-Methods for Product Engineering and anticipative Industrial Engineering
MTM-Methods for corrective Industrial Engineering
Design and development support Planning, operations and improvement support
Productivity Management of Work Systems with MTM-Methods
1.Product development 2.Process development 3.Operation & improvement
SOP
Productivity Ramp Up
Productivity progression with MTMhigher productivity at SOPsteep rise of productivity after SOP
Lean and MTM – scientific, practical and educational perspectives to enhance productivity
Productivity Management by MTMP
reven
tio
n
Su
sta
inab
ilit
y
Design evaluation(Value analysis, QFD)
Assembly oriented productdesign (ProKon)
Technical calculation
Supply and actualise bill of activities/work plan with target times
Task analysis and synthesis, task relevance analysis
Process analysis and documentation (Flow charts, table visualisation)
Process modelling and improv. with MTM process building block systems
Supplementary techniques (estimate, standard data, process time eval)
Layout planning
Ergonomic Assessment
Planning and implementing ofwork systems
Ramp-up & shop floor management
Supplementary techniques(self-recording, time measurment, work sampling,…)
Target time analysis and synthesis (target and lead times)
Value Stream Mapping
Company-specific building block systems / target time management
Personnel requirement planning and controlling
Improvement management
(labor) time management
Renumeration differentiation
Project management
1.Product development 2.Process development 3.Operation & improvement
Source: Bokranz/Landau, 2012
MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 17
…looking forward to answering your questions!
Contact:
Prof. Dr. Peter Kuhlang Head of MTM-Institute
German MTM-Association MTM-Institute Eichenallee 11 15738 Zeuthen Germany
Tel.: +49 33762 20 66-31 Fax: +49 33762 20 66-40 Mobil: +49 151 4225 1234 [email protected] www.dmtm.com