Was presented at MTM Turkey Conference im 16.05.2014 by Guillaume Lachevre

1. MTM and Lean Case study
MTM and Lean Case Study
By Guillaume Lachèvre
MTM Productivity Group France
Guillaume.lachevre@mtmpg.fr

2. MTM and Lean Case study
Introduction
• Lean and MTM are world wide use to reach the
maximum efficiency of a production
• Lean reach a high level of productivity based on
a global analysis of thee process
• MTM reach a high level productivity on a local
analysis of the process
• Combination of both concepts bring to High level
of efficiency

3. MTM and Lean Case study
Presentation
• Case study on a batch
production of outdoor cooking
appliances
• Highly seasonable products
(70% of the production in 4
months)
• Production on a “old fashion line”
• 25 different references on the
line, 3 major family: gas, electric,
combo (electric and gas)
• AS IS situation with a stop and
go strait line, 4 operators.

4. MTM and Lean Case study
AS IS
Balancing made by function
• WS1: frame assembly
• WS2: electrical and gas assembly
• WS3: normative control
• WS4: accessories and packing
 produce 50 parts / days = 7,5 part/hours

5. MTM and Lean Case study
AS IS
Small
Components
for WS 1
Small
Components
for WS 2
Small
Components
for WS 3
Small
Components
for WS 4
Change of components batch 1 per shift
Stock
S
t
o
c
k
S
t
o
c
k
S
t
o
c
k
Components
for WS 1
Components
for WS 2
Components
for WS 3
Components
for WS 4

6. MTM and Lean Case study
AS IS
• Flexibility:
 1 reference per day
 No place for more or less operators
• Efficiency:
 No time measurement
 Operators to defines production target
 First operator wait until last operator
finished the last product of the day
• Reactivity:
 Setup time = 2h made 1 time per day
 Production to stock
 No database to react quickly to a new
product
NEED of a complete reorganization of the line

7. MTM and Lean Case study
AS IS
• Reduce Stocks
• Increase flexibility (customer
oriented production)
• measure efficiency
• Improve production reactivity

8. MTM and Lean Case study
Project Team
• Project Coordination: G. Lachèvre (external)
• Project team composition:
• Lean Group:
• 1 Industrial engineer (internal)
• 1 logistic engineer (internal
• MTM Group
• 1Industrial engineer ((internal)
• 1 consultant from thee MTM Productivity Group
• Sponsored by Top Management with support of all
services…
• Use of MTM and line balancing software Equinoxe

9. MTM and Lean Case study
Main Tasks
• Setting up a milk-run
• Modification of Layout (U shape)
• Setting up a batch size
• Use of all other Lean tools (TPM, 5S, Kanban, …)
• To furnish Time database for all aspect of
production
• To decide best practice for assembly
• to implement a efficiency measurement
• To implement a reactive task force to improve
efficiency

10. MTM and Lean Case study
MTM Tools
Association MTM Française
42 Ave Montaigne 75008 Paris
Tél : + 33 (0) 1 53 6744 75
Email : contact@mtmpg.fr
SOL
Standard Operations
Logistics
L’utilisation de ces valeurs de tables sans une formation approfondie en MTM-UAS et MTM
Logistique, peut conduire a des résultats erronés.
Tracteur électrique 4LT TMU
Conduire
Intérieur
Avec remorque (/ m) EFIM 13
Sans remorque (/ m) EFIO 10
Extérieur
Avec remorque (/ m) EFAM 13
Sans remorque (/ m) EFAO 7
tourner 90°
Avec remorque (/ m) EFKM 92
Sans remorque (/ m) EFKO 38
Arrêt
(décélération et
accélération)
Avec remorque (/ m) EFVM 56
Sans remorque (/ m) EFVO 30
Accrocher
Avec Alignement EANM 368
Sans alignement EANO 258
Décrocher
Avec Alignement EABM 285
Sans alignement EABO 182
Addition Remorque supplémentaire EAZZ 200
Tire-Palette 5LT TMU
Tracter
Tracter par m
≤ 500 kg HFFA 30
> 500 kg HFFB 35
Tourner 90°
≤ 500 kg HFKA 15
> 500 kg HFKB 19
Arrêt
(décélération et
accélération)
≤ 500 kg HFVA 80
> 500 kg HFVB 150
Enlever
palette
Avec Alignement
≤ 500 kg HAMA 520
> 500 kg HAMB 615
Sans Alignement
≤ 500 kg HAOA 350
> 500 kg HAOB 415
Poser palette
Avec Alignement
≤ 500 kg HPMA 295
> 500 kg HPMB 310
Sans Alignement
≤ 500 kg HPOA 125
> 500 kg HPOB 130
Alignement additionnel
≤ 500 kg HRZA 125
> 500 kg HRZB 190
Chariot manuel 4LT TMU
Pousser par m
≤ 50 kg WFA 25
≤ 100 kg WFB 28
≤ 200 kg WFC 30
> 200 kg WFD 35
Tourner 90°
≤ 50 kg WKA 15
≤ 100 kg WKB 11
≤ 200 kg WKC 8
> 200 kg WKD 8
Arrêt (décélération et
accélération)
≤ 50 kg WVA 35
≤ 100 kg WVB 45
≤ 200 kg WVC 80
> 200 kg WVD 105
Alignement additionnel
≤ 50 kg WRA 80
≤ 100 kg WRB 105
≤ 200 kg WRC 160
> 200 kg WRD 215
AA/JG © MTM-Institut
Copyright déposé! Reproduction interdite!
• Use of MTM Standard
Operation logistic
• Defining time for a
Run  definition of a
production Batch size
• Milk run used on other
line of the plant
• Coordination with
supplier to reduce
manipulation

11. MTM and Lean Case study
MTM tools
motion length
in cm
≤ 20
> 20
to
≤ 50
> 50
to
≤ 80
distance range 1 2 3
Get and Place Code
1 2 3
TMU
≤1
daN
easy
approx. AA 20 35 50
loose AB 30 45 60
tight AC 40 55 70
difficult
approx. AD 20 45 60
loose AE 30 55 70
tight AF 40 65 80
handful approx. AG 40 65 80
> 1 daN
to
≤ 8 daN
approx. AH 25 45 55
loose AJ 40 65 75
tight AK 50 75 85
> 8 daN
to
≤ 22 daN
approx. AL 80 105 115
loose AM 95 120 130
tight AN 120 145 160
Place Code
1 2 3
TMU
approx. PA 10 20 25
loose PB 20 30 35
tight PC 30 40 45
motion length
in cm
≤ 20
> 20
to
≤ 50
> 50
to
≤ 80
distance range 1 2 3
Handle Aid Code
1 2 3
TMU
approximate HA 25 45 65
loose HB 40 60 75
tight HC 50 70 85
Operate Code 1 2 3
simple BA 10 25 40
compound BB 30 45 60
Motion Cycles Code 1 2 3
one motion ZA 5 15 20
motion sequence ZB 10 30 40
shift and one motion ZC 30 45 55
tighten or loosen ZD 20
Body Motions Code TMU
walk / m KA 25
bend, stoop, kneel (incl.
arise)
KB 60
sit and stand KC 110
Visual Inspection VA 15
• Use of MTM-UAS to
build operation
Standard Time
• Creation of Data
block per function
• Creation of products
with these bocks
• Use of software EQUINOXE

12. MTM and Lean Case study
Exemple Measurement
Small
Components
for WS 1
Components
for WS 1
2 m
Components for WS 1
Displacement of 2x2
meters 4 times per
cycles
MTM Calculate that the gain is
KA x 2 x2 x4 = 25 TMU x 16 = 400 TMU
= 14 s per cycles = 10% of cycle time
No Displacement

13. MTM and Lean Case study
Advantage
• MTM Bring measurement
to operation to determine
gains and best solution
for improvements
• Used to calculate Return
On Invest
• Creation of a standard
database for new
products

14. MTM and Lean Case study
Assembly Line
• U line
• Products on trolley
• Operators pushing trolley from 1
zone to the other
• Full cycle include: Assembly,
wiring, electrical control and
packing
• operator working in 1 or several
zone (depending on balancing)
• Impossible for an operator to
perform a full cycle (competences
and quality)
• Nominal balancing: 4 operators
• Component feeding by milk run;
exact number for the batch

15. MTM and Lean Case study
Database creation
• 1 dedicated software: A modification of an operation affect all products on which it is made
• For each operation: zone, VA or NVA, rest allowance and MTM-UAS standard time
• Creation of the reference product, depending on the forecasted production mixt
• Balancing of the high runner
• Balancing of the remaining operation for the next product (by order of importance in the production
mixt)
 a common operation will always be performed at the same place
Standard Operations
MTM UAS analysis
Products
Cross table
operation per product
Balancing
5 op
Balancing
AS IS
Balancing
3 op
Balancing
4 op
Production mixt

16. MTM and Lean Case study
To BE

17. MTM and Lean Case study
Balancing per function
10,37
74%
Cadence 12,8 Cadence 9,7 Cadence 12,7 Cadence 10,0
Perfomance 80% Perfomance 81% Perfomance 88% Perfomance 71%
weight 7,44% weight 5,17% weight 2,09% weight 54,62%
Cadence 12,3 Cadence 9,3 Cadence 12,1 Cadence 9,4
Perfomance 79% Perfomance 76% Perfomance 86% Perfomance 73%
weight 13,52% weight 3,85% weight 1,03% weight 12,29%
Cadence
Perfomance
BALANCING AS IS
Produit de REF
65,78%
61,69%
100,00%
69,50%
0,00%
100,00%
1 2 3 4
GXX3T
57,33%
66,22%
97,62% 100,00%
0,00%
100,00%
1 2 3 4
GXX3M
60,03% 62,03%
100,00% 95,94%
0,00%
100,00%
1 2 3 4
GXX4T
68,71%
83,63%
100,00% 99,83%
0,00%
100,00%
1 2 3 4
GXX4M
71,08% 77,09%
100,00% 95,32%
0,00%
100,00%
1 2 3 4
XTX4T
65,06% 57,56%
100,00%
62,39%
0,00%
100,00%
1 2 3 4
XTX4M
71,19%
61,55%
100,00%
58,92%
0,00%
100,00%
1 2 3 4
XXF3T
74,78% 80,88%
100,00%
68,62%
0,00%
100,00%
1 2 3 4
XXF3M
69,36% 70,84%
100,00%
65,34%
0,00%
100,00%
1 2 3 4

18. MTM and Lean Case study
Balancing principle
• MTM determine times per operation
• Creation of equivalent workload for each
operators
• Creation of addresses of component on he
line
balancing is made on a time database (not
per function)
Balancing made on reference product
(weighted average of production)

19. MTM and Lean Case study
Balancing 4 op
13,94
99%
Cadence 15,1 Cadence 11,2 Cadence 13,3 Cadence 13,7
Perfomance 93% Perfomance 93% Perfomance 90% Perfomance 98%
weight 7,44% weight 5,17% weight 2,09% weight 54,62%
Cadence 14,8 Cadence 11,0 Cadence 13,0 Cadence 12,5
Perfomance 96% Perfomance 90% Perfomance 92% Perfomance 97%
weight 13,52% weight 3,85% weight 1,03% weight 12,29%
Cadence
Perfomance
BALANCING 4 OPERATORS
Produit de REF
98,94% 100,00% 99,73% 99,25%
0,00%
100,00%
1 2 3 4
GXX3T
85,71% 92,75% 100,00% 94,45%
0,00%
100,00%
1 2 3 4
GXX3M
95,42% 94,87% 100,00% 92,43%
0,00%
100,00%
1 2 3 4
GXX4T
87,47%
100,00% 90,91% 83,40%
0,00%
100,00%
1 2 3 4
GXX4M
96,18% 100,00%
88,88% 81,54%
0,00%
100,00%
1 2 3 4
XTX4T
95,30% 97,96% 97,90% 100,00%
0,00%
100,00%
1 2 3 4
XTX4M
100,00% 99,03% 96,81% 91,36%
0,00%
100,00%
1 2 3 4
XXF3T
100,00% 94,99%
84,26% 91,12%
0,00%
100,00%
1 2 3 4
XXF3M
100,00%
85,83% 84,25% 89,38%
0,00%
100,00%
1 2 3 4

20. MTM and Lean Case study
Results for the
average product
per function 4 OP 3 OP 5 OP
performance 74,1% 99,6% 98,9% 95,7%
nb of
operator
4 4 3 5
Balancing
loses (s)
-357 -5 -11 -46
Cadence
(P/H)
10,38 13,98 10,42 16,80
Productivity 34,68% 33,84% 29,51%
All Info are available for all products in a bijective way
production objectives  Nb of operators requested
Nb of operator available (absenteeism)  production objectives
Based on MTM standard time

21. MTM and Lean Case study
Non
Quality
Waste
operation
Frequencial
NVA
Cyclic
NVA
Operator
efficiency
AddedValue
ConceptionTime
Design
coefficient
Efficiency coefficient
KE
Support
functions
Tempsattribuéausecteur
Global
organisation
breakdo
wn
Spendtime
Production
datas
MTM
Paid hollidays
allowance
Accountancy datas
Paidtime
Setting an efficiency
measurement

22. MTM and Lean Case study
Setting an efficiency
measurementDates: 24/02/2013 KE 86,11%
Line: E target KE 80%
products GXXF3456m
70
65
60
55
50
45
40
35
30
25
20
15
10
5
1 2 3 4 5 6 7 8 TIME
h expected made
1 10 7
2 20 24
3 25 25
4 35 27
5 40 29
6 50 44
7 60 58
8 72 62
Balancing : 4 op
Production report sheet
Front panel issue not punched at the back
support from another operator switching to 4 op
balancing
gas test machine default
Team Leader: XXXXXXXX
X
X X
X X
X
X
X

23. MTM and Lean Case study
Efficiency measurement

24. MTM and Lean Case study
Results
• Increasing of efficiency from 65% to 87%
 with measurement we can improve
• Support service can categories the loses and check the
nb of product lost
 better reactivity of services
• Choice to get:
• 3 operators for low season
• 5 operators for High season
 Better flexibility
Most important Operators are now asking for
generalization of the system

25. MTM and Lean Case study
• With MTM we can now measure any kind
of product from the line…
• Even the most sophisticated one

26. MTM and Lean Case study
Guillaume LACHÈVRE
MTM Instructeur
Email: guillaume.lachevre@mtmpg.fr
Mobile: +33 (0)6 80 74 44 34