APC performed standard and a methods-time measurement (MTM) time study for Motherson’s three plants located in Cottondale and Vance, AL. Motherson is the largest tier one suppler to Mercedes-Benz U..S. International (MBUSI). At this facility Motherson produces injection molded parts such as bumpers, door panels, rocker panels, running boards, spoilers and many other components for nearby MBUSI. The parts are produced in accordance with MBUSI’s broadcast in a Just-In-Time and In-Sequence style. Meaning that most Motherson product is assembled on a finished Mercedes-Benz vehicle the same day that the product is ordered and produced. The sequence of parts that Motherson ships to MBUSI matches the sequence of cars being produced by Mercedes from the model, included options, and the color of the bumper.
MBUSI demands that suppliers maintain the constant flow of parts to the final assembly line without interruption. This creates a challenge for suppliers to accurately balance their own assembly lines in an efficient manner because testing new and potentially cost-saving improvements can only be done with an assurance that the flow of parts remains un-interrupted. For Motherson to be able to more accurately gauge improvement opportunities they partnered with APC to perform time studies throughout their facilities serving MBUSI. APC began this work by performing standard time-studies for each assembly line.
Once the standard time studies had been completed, Motherson asked for a more detailed MTM time study. For this time study APC utilized the Maynard Operational Sequence Technique (M.O.S.T.). M.O.S.T., as do each MTM system, utilizes a predetermined expected time that each motion of an operation takes to perform. APC analyzed more than 500 workstations. Each workstation’s required movement was broken down to the smallest of details such as how many steps were taken, each grasp of a tool or part, every time a part was snapped together. Once the motions of the workstation were established, M.O.S.T. was applied using a custom tool that was developed by APC to automatically produce Yamazumi charts, Value vs. Non-Value Add Charts, and Standard Work Combination charts.
In order to allow the time studies to become a living document for continuous improvement for Motherson, APC provided training on both M.O.S.T. and the APC custom tool to more than a dozen Motherson employees. Motherson has already utilized the time studies to re-evaluate the installation of their latest assembly line before it was even complete with intentions of increasing investment by $350,000. Overall, the project is estimated to provide an impact of $7,377,394 with time and cost reductions expected to be at least $6,808,809 annually. During the course of this project, fifteen University of Alabama student interns with varied backgrounds were provided an excellent opportunity to learn about time studies, M.O.S.T., manufacturing in Alabama.
Credits:
Created with an image by moccabunny - "Professional hand checklist and check time."