The Time Analysis of Material Flow with Methods Time Measurement
- Contribution to CSR Implementation at the Level of Industrial
Production II.
Rastislav Beňo1, Gabriela Hrdinová1, Peter Sakál1, Ľubomír Šmida1
1
Slovak University of Technology in Bratislava,
Faculty of Materials Science and Technology in Trnava,
Paulínska 16, Trnava, 917 24, Slovakia
a
rastislav.beno@stuba.sk, b gabriela.hrdinova@stuba.sk, c peter.sakal@stuba.sk,
d
lubomir.smidal@stuba.sk
Keywords: Material Flow, Method Time Measurement, CSR, Ergonomics
Abstract. The importance of forming and implementation the socially responsible society is
highlighted by report on the creation of conditions for CSR in Slovakia. Recommendations’ arising
from the report defines the starting points, from which for the article is chosen motivate companies
to attend the United Nations Global Compact and other networks that support CSR, as well as the
need for the integration of CSR and sustainable development issues in educational process [1, 2, 3,
4]. Companies that support the initiative, as well as direct implementation of the CSR must take
action leading to its successful implementation in all areas of business processes, including the
logistics and material flow. In the analysis of material flows should be respected the limiting factor
of physical load in handling and transport activities that affect the setting of time norm that is
required for realization of work activity. The time analysis of material flow allows the identification
of time consumption for individual work actions, which are needed during realization of work
operation. For time analysis of material flow realization we can use the Method Time Measurement.
More specifically, we can use the Method Time Measurement – Logistic, which is the subject of
this article. Selection of the method is a logical step, which resulted from the needed of
responsibility in area of exact decision-making and objective assessment of the efficiency of
material flows for minimizing the impact of risk factors. The article provides the information about
characteristic of mentioned method, it describe the possible areas of using the method and presents
the illustrative example of practical application of method for time analysis of material flow,
whereby the main emphasis is on the social aspect of corporate social responsibility through
ergonomics and the effectiveness using of time during the work operations realization within the
framework of material flow
Introduction
Material flow is a necessary part of industrial production, with an organized movement of
materials, auxiliary materials, raw materials, intermediate products, tools, as well as packaging and
waste. It is defined by the frequency, intensity, duration, performance, direction and handling
factor. Material flow is a suspension of added value creation of the final product, but it cannot be
from the production process completely eliminated. The importance of analysis of material flow
increases with a sustainable and efficient use of available resources and use and work with these
resources is not a risk to maintain a permanent safety and ergonomic conditions for employees and
can also generate a contribution to creating and implementing a socially responsible enterprise. Due
to the fact that material flow attaches considerable funds and staff, warehouse or manufacturing
space and especially time, which is the best quantifiable parameter, is the time analysis of material
flow suitable tool for identifying the effectiveness of its implementation and progress.
The implementation of time material flow analysis should be carried out in order to hold the
concept of corporate social responsibility, which should move the company toward sustainable
development and to link its economic development with social inclusion and environmental
capacity.
Because the issue of formation and implementation of social responsibility at the enterprise level
is still the subject of major discussion, it should become a strategic priority for the focus on the
creation of conditions for its successful implementation in enterprise processes.
These facts have created the necessity of the article, which aim is to raise awareness of social
responsibility, creating pressure on private and public sector and the population of the necessity of
its creation and use at every level enterprise processes, logistics and material flow including.
Problem Definition
The effectiveness of material movement is subject to material flow analysis of at each stage of
the manufacturing process. Through the analysis of material flow we examine the requirements for
transport, handling and storage processes in their mutual relations, we define weak points through
their identification and we provide areas of rationalization.
The main principles of optimal organization of material flow and creation of production layout,
as is mentioned by [5] include:








minimization of transport performances and transportation costs,
minimization of surfaces
ensure safety and hygiene requirements
flexibility and possibility of change in the future,
suitability for teamwork
minimization of inventory and intermediate times,
simple material flow,
connection to external logistics chain.
The practice proves that the complexity of the realization of material flow analysis increases
with the number of production of large quantities of products in different varieties, or storage of a
wide range of goods of different packages from different suppliers and with an unequal amount of
removal from storage. In this case it is necessary to consider a group of factors that can individually
but also cumulatively effect on the efficiency of material flow.
The following factors according to [6] represent a core set of factors affecting just the efficiency
of the solution of material flow:







external transport connection,
production volume,
number of parts or material,
number of operations of parts or materials,
number of nodes or assembly groups
shape and dimension of the area or areas,
parameters of the material flow between objects.
Method of Analysis
The time analysis of material flow, which is appropriate to define its effectiveness, as stated in
the introduction can be realized using the method of Method Time Measurement - Logistics. Before
the model example of its use, there is briefly introduced the methodology of Method Time
Measurement (MTM) and then the module MTM-Logistics.
MTM method is one of the most common methods of motion study. It was developed as a
system of predetermined times and published in the book "Method-Time Measurement" in 1948 in
the USA by Harold B. Maynard, G.J. Stegemert and J.L. Schwab. This system has become a
reference standard and the majority of current pragmatic solutions [7].
MTM creates modus operandi through the description, structuring, planning and analysis /
synthesis using time-defined content and process elements. With MTM procedures are
systematically distributed, presented and visualized influence quantities.
MTM method is used in the optimization and rationalization of work and the workplace. It is one
of the tools for the study of human labour and time that can be used in every industry. The great
advantage of this method is that time values and MTM standards are internationally valid.
One of conditions for effective use of MTM method is an accurate description of the analysis
work procedure. This description is achieved by using appropriate codes for each selected basic
movement. Categories of basic movements and their label are processed in tables [8].
In order to define basic movements and provide for these movements necessary time, it was
microfilmed a large number of industrial work processes. Based on the movie analyses was set
normalized performance as a performance medium-skilled, apprenticeship worker who can perform
this performance a long time without over fatigue.
During the development of MTM method, developers have formulated individual requirements
for MTM process that are characterized by the fact that procedures are applicable in every
economic sector, it also must be well understood procedure and can be learned without special
knowledge, the procedure must be created such a way that realization time for the method resulted
from itself and at the end, procedures must be used equally on international level.
Normed times of MTM were processed by statistical methods, mainly calculation of influence
quantities, such a manner that offset by differences related to the measured values [9].
Time values of basic movements are very small and cannot be measured in conventional units of
time. Therefore it was introduced for MTM method and later also for the needs of other methods
unit TMU (Time Measurement Unit), which are listed in Table 1 below.
Table.1. Experimental Results of Uniform Random
TMU
1
27,8
1666,7
100000
Seconds
0,036
1
-
Minutes
0,0006
1
-
Hours
0,00001
1
Currently, there are several systems of analysis of methodology MTM, which are presented as
follows [9]:
 MTM-1 - is a basic module, whose knowledge is essential to the further development and
work in the area of MTM,
 MTM-2, MTM-SD-BW - suitable for mass production with a high degree of repeatability, to
the modus operandi of a longer cycle, used in supplier companies, automotive and electronics
industries,
 MTM-UAS - suitable for batch custom manufacture with repetition; work cycle length is
significantly longer than in large batch, used by companies in the automotive and electronics
industries and also in logistics,
 MTM-MEK - suitable for custom pieces and small batch production, without repetition,
possibly with occasional repetition, used in engineering and metallurgy, manufacture of
aircraft, but also in maintenance and repair, assembly and logistics,
 MTM-ERGONOMICS - the aim is the best anticipation of the production planning based on
established physical load MTM analysis of the worker;
 MTM-LOGISTICS - this methodology can significantly contribute to the organization,
creation and analysis of logistics processes, while provides for the enterprise structured and
associated process components for transport and handling.
Time Analysis of Material Flow with Methods Time Measurement - Logistics
Regard to the subject of the article that is the time analysis of material flow by MTM - Logistics
in the following pages is briefly characterized.
The focus of MTM was in 80s in the evaluation and creation of transport tasks, creating places
for packaging and testing, and evaluation of the commissioning activities. Parallel to the
development of a comprehensive entrepreneurial-oriented view of logistics, the use of MTM and
for evaluation formation of logistic processes in recent years has been increasing.
Within the logistics activities in different business activities are using the similar processes
(procedures), with considerable repetition. These typical processes that vary in their complexity are
called the standard logistic processes. Therefore, MTM develops and provides aggregated
processing components created for use in enterprise production.
The development of process of the standard elements logistics operations is not yet complete.
The development of process elements is proceeds by the following general process conditions [10]:
 standard procedures run on orders, which are characterized by frequent repeatability and thus
worker has the option of routine learning curve,
 worker has a job and transport means for carrying out work tasks,
 jobs are created by the spectrum of tasks.
For the practical and quick use of the method, there is a system of codes, while contain all the
elements 12-digit code, where the first place for coding is always addressed to a particular
hierarchical level.
The last place of the coding shows which elements of MTM system was used to determine the
time. For the standard methods of logistics represents number 5 the system of MTM - UAS. In the
last place of the code can stand P as process time, or at the level of process succession can be in the
last place L for elements, which consists of UAS - process elements and process times.
Empty spaces in coding are indicated by dots. The data cards are encoding in abbreviated form,
starting with the first place, disregarding the dotted points and the last place in the coding.
Coding of the processes performed by the system of data cards, in which are defined individual
activities and tasks that have assigned appropriate code and time value in units of TMU (1 TMU =
0.036 s = 0.0006 min). An example of data card with an example of the coding in methodology
MTM - Logistics for transport is shown in Table 2 respectively in Fig.. 1 [10].
Table.2. Example of MTM – Logistics data card
Process steps for transport - general
elements
Code
shifter
ABH
18
joystick
ABJ
10
start and switch off the
engine
AZM
90
get in and get out from
the driver's seat
AZA
220
pull and release the
handbrake
AZF
120
open and close the
driver's door
AZT
100
fasten and unfasten the
safety belt
AZS
175
walking per meter
KA
25
bend, kneel, including
stand up
KB
60
manipulation
by
additional
values
body
movements
4LT
TMU
place
1
4
2
L
3
T
4
A
5
.
6
.
Level
hierarchy:
process
steps
Logistics
Transport
General
Type of
activity
Activities
Fig.1. MTM – Logistics coding for transport
The following provides a concise example of the realization of static simulation using time
analysis of material flow through MTM-logistics. An example is realized through process steps for
the sliding mast forklift stacker (FS) and is complemented by a table for clear illustration of decay
of work operation on individual sections.
Table.3. The disintegration of the working operation by MTM - Logistics coding
N. 1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.
15.
16.
17.
18.
19.
20
.
21.
22.
23.
24.
25.
26.
Description Code TMU Nr x Mlt TotalTMU
walking to FS
25
5
125
KA
get in and get out from the driver's seat
220
1
220
AZA
175
1
175
fasten and unfasten the safety belt
AZS
190
1
190
start and switch off the engine
AZM
120
1
120
pull and release the handbrake
AZF
forks lift to 10 cm above the floor and put down again 4LTSHPAS 15
2
30
delay to the first start and the last stop FS
1
30
4LTSFVUS 30
FS directed to 90 ° to the driving direction (in
1
55
4LTSRFSS 55
reverse)
delay to start and stop (unloaded)
1
30
4LTSFVUS 30
delay to start and stop (loaded)
1
56
4LTSFVBS 56
driving from store to assemble and back (per 1 m)
13
2×30
780
4LTSFISS
ride in 90 ° curves (4 per path)
2×4
128
4LTSFKSS 16
FS directed to 90 ° to the stack
1
70
4LTSRLSS 70
lift forks up to a height of 1 m
0,9
51
4LTSHHUS 56
forks inserted into the folding box
1
95
4LTSGPKS 95
goods (box) raise to a height of 10 cm
1
15
4LTSHPAS 15
goods (box) from the stack
1
120
4LTSTKSS 120
lowering on the floor (at 1 m)
1
56
4LTSHSBS 56
lifting platform tilted by 3 ° to the truck and back
2
72
4LTSVHNS 36
FS directed to 90 ° to the driving direction (in
1
55
4LTSRFSS 55
reverse)
FS directed to 90 ° to the place of storage
1
70
4LTSRLSS 70
goods (box) on pallet
1
120
4LTSTKSS 120
goods (box) put down from 10 cm
1
15
4LTSHPAS 15
forks from the folding box
1
95
4LTSGPKS 95
FS directed to 90 ° to the driving direction (in
55
55
4LTSRFSS 55
reverse)
actuation by joystick
10
18
180
4LTABJ
∑3008
Sample
From the warehouse to the assembly hall of cars through sliding mast FS are transported as
necessary parts for assembly. Parts for mounting are transported in folding boxes, and these are
stacked at 1m high from the floor. Folding boxes are unloaded in the assembly hall on palette,
which lies on the ground. Start is walking to Measuring FS at a distance of 5 meters and the end is
an FSer orientation of FS in the reverse driving direction. The road from the warehouse to the point
of unloading is 30 m and the amount of curves per trip represents 4.
Results and Conclusion
Realized static simulation of time analysis of material flow, which is followed to transport parts
to production showed that total time required for its realization is 3008 TMU, which when
converted into the basic unit of time expressed in seconds, gives 108.288 sec. respectively. 1.8048
min.. Total time during the employee work, which ensures delivery of the required number of parts
in production, would ultimately depend on the necessary parts for production cars.
Results of the analysis should be used for more effective material flow, especially its time
course. Finally, it is necessary to realize streamlining at such level that the employee was not
overloaded in terms of ergonomics, which may ultimately lead to errors in terms of the decision
making and process realization and especially to the potential damage of health.
In case that results of the analysis will lead to a level of rationalization of labor and material flow
processes that are socially responsible, flexible, and will lead to the development of employees and
the enterprise taken as a whole, the company can achieve sustainable competitiveness in the current
turbulent market conditions, as well as in the future.
In relation to that in the end is necessary to note that the use of MTM can bring various benefits
such as unquestionably the analytical approach, creation of potentials for process improvement,
predictable and quantifiable logistics processes, etc.. However, implementation of the analyses of
MTM should be realize solely by persons who are for these types of analyses properly trained with
practical skills to avoid acquiring incorrect conclusions, and thus a negative influence for the results
of analyses that are necessary to ensure continuity and sustainability of production, safety and
production ergonomic conditions of employees and meeting customer needs.
Acknowledgments
This paper was supported by the Slovak Research and Development Agency under the contract
No. LPP-0384-09: “Concept HCS model 3E vs. Concept Corporate Social Responsibility (CSR).”
The paper is also a part of submitted KEGA project No. 037STU-4/2012 “Implementation of the
subject “Corporate Social Responsibility Entrepreneurship” into the study programme Industrial
management in the second degree at MTF STU Trnava”.
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