Time & Motion Study Services

Time and Motion Study is a fundamental industrial engineering technique used to understand how work is performed, how much time each activity requires and where opportunities exist to improve productivity.

Our Time and Motion Study Services help manufacturing organisations measure work accurately, identify unnecessary movements and delays, establish realistic standard times, optimise work methods and improve manpower and machine utilisation. With more than 25 years of industrial experience, we combine traditional work measurement techniques with modern data analysis, lean manufacturing and process improvement approaches to develop practical and measurable improvements.

Time study focuses primarily on how much time a task requires, while motion study examines how the task is performed and how unnecessary movements can be eliminated. When used together, they provide a powerful foundation for productivity improvement, line balancing, capacity planning, manpower planning and production control.

Our Time & Motion Study Approach

Our approach begins with understanding the operation, its purpose, production requirements and current method of working. We then observe and measure the process systematically.

A typical study involves:

• Understanding the production process

• Defining the operation and work elements

• Observing the existing work method

• Recording work cycles

• Measuring element-wise time

• Analysing operator movements

• Identifying delays and interruptions

• Evaluating performance variations

• Determining normal performance

• Applying appropriate allowances

• Establishing standard time

• Identifying improvement opportunities

• Developing an improved work method

• Validating the proposed improvement

The objective is not simply to record how long an operation takes, but to determine how the work can be performed more effectively and consistently.

Time Study

Time study involves the systematic measurement of the time required to perform a defined operation using an established method.

We conduct time studies to determine:

• Cycle time

• Element time

• Average observed time

• Normal time

• Performance-adjusted time

• Allowances

• Standard time

• Output potential

• Manpower requirement

• Machine requirement

Time study can be performed using direct observation, stopwatch-based measurement, video analysis or digital data where appropriate.

Accurate time measurement provides a reliable basis for production planning and operational decision-making.

Motion Study

Motion study examines the physical movements involved in performing an operation.

We analyse movements such as:

• Reaching

• Picking

• Moving

• Positioning

• Turning

• Walking

• Searching

• Handling

• Loading

• Unloading

• Inspection

• Tool movement

• Material movement

The objective is to identify unnecessary or excessive motion and develop a simpler, safer and more efficient method.

Reducing unnecessary movement can improve productivity while also reducing operator fatigue and improving workplace ergonomics.

Element-Wise Work Measurement

Complex operations are divided into smaller and clearly identifiable work elements.

For example, an operation may be divided into:

1. Pick material

2. Position material

3. Perform processing activity

4. Inspect

5. Move finished component

6. Prepare for the next cycle

Each element can then be measured separately.

Element-wise analysis makes it easier to identify where time is being consumed and which activities offer the greatest opportunity for improvement.

Cycle Time Analysis

Cycle time is one of the most important indicators in manufacturing productivity.

We analyse cycle time across multiple production cycles to identify:

• Average cycle time

• Minimum cycle time

• Maximum cycle time

• Time variation

• Abnormal cycles

• Delay elements

• Bottleneck elements

• Repeatability issues

This helps distinguish between the actual processing time and time losses caused by interruptions, waiting, material shortages, machine issues or inefficient methods.

Standard Time Determination

One of the major outcomes of a properly conducted time study is the establishment of standard time.

Standard time provides a realistic benchmark for the time required to complete an operation under defined working conditions.

It can support:

• Production planning

• Capacity planning

• Line balancing

• Manpower planning

• Cost estimation

• Production target setting

• Productivity measurement

• Performance monitoring

• Production scheduling

A properly established standard time should reflect the actual process, working conditions and appropriate allowances rather than an arbitrary target.

Performance Rating & Allowances

Observed time alone does not necessarily represent standard time.

We consider relevant factors such as:

• Operator performance

• Working conditions

• Process characteristics

• Fatigue

• Personal requirements

• Necessary delays

• Machine-related interruptions

• Material handling requirements

Where applicable, performance rating and appropriate allowances are incorporated to arrive at a practical standard time.

This helps ensure that standards are realistic, achievable and suitable for operational use.

Method Improvement Through Motion Analysis

Time study tells us where time is being spent. Motion study helps determine why time is being spent.

We analyse the existing method to identify opportunities such as:

• Eliminating unnecessary movements

• Combining activities

• Reducing walking

• Improving material positioning

• Repositioning tools

• Improving workstation layout

• Reducing reaching distance

• Improving material presentation

• Simplifying handling

• Improving work sequence

The improved method is then evaluated to determine its potential impact on cycle time and productivity.

Workplace Layout & Ergonomics

Workstation design has a direct influence on motion, cycle time and operator fatigue.

Our studies can evaluate:

• Operator working position

• Tool location

• Material location

• Reach distance

• Work height

• Material presentation

• Workstation arrangement

• Movement paths

• Handling requirements

Improved workplace ergonomics can reduce unnecessary movement and make the work easier and more consistent.

Manpower Planning

Time and motion study provides valuable information for determining manpower requirements.

By understanding standard times, production requirements and available working hours, organisations can estimate:

• Required manpower

• Operator loading

• Workstation requirements

• Shift requirements

• Production capacity

• Additional manpower requirements

• Potential manpower optimisation

This can help prevent both overstaffing and excessive workload concentration.

Line Balancing

Standard times generated through time study are an important input for production line balancing.

We compare the time required at each operation and identify:

• Bottleneck operations

• Underloaded operations

• Overloaded workstations

• Operator imbalance

• Capacity mismatch

• Excess waiting

• Opportunities for task redistribution

Work elements can then be redistributed where practical to create a more balanced production flow.

Productivity Measurement

Time and motion study establishes a measurable relationship between work content and available production time.

This enables organisations to monitor indicators such as:

• Actual output

• Standard output

• Production efficiency

• Labour productivity

• Operator utilisation

• Machine utilisation

• Cycle-time adherence

• Standard versus actual time

• Productivity losses

This provides management with a more objective basis for evaluating operational performance.

Identifying Productivity Losses

A detailed study can reveal losses that may not be visible in conventional production reports.

These can include:

• Waiting

• Excessive walking

• Searching

• Material shortages

• Poor material placement

• Machine idle time

• Unnecessary handling

• Excessive inspection time

• Rework

• Poor workstation arrangement

• Unbalanced workloads

• Process interruptions

• Unnecessary movement

Once these losses are quantified, improvement activities can be prioritised based on their potential impact.

Video-Based Time & Motion Study

Where appropriate, video recording can be used to analyse complex or repetitive operations.

Video-based analysis allows individual work elements and movements to be reviewed repeatedly and can be particularly useful when:

• The operation is very fast

• Multiple movements occur simultaneously

• The process has considerable variation

• Several operators are involved

• Detailed motion analysis is required

• Management requires visual validation

Video analysis can also help compare the existing method with the proposed improved method.

Time Study for Production Planning & Capacity

Standard times provide an important foundation for production planning.

By combining standard time with order quantities, available working hours, manpower and machine availability, organisations can estimate production requirements and capacity.

This supports:

• Production planning

• Scheduling

• Capacity calculation

• Delivery planning

• Manpower planning

• Machine loading

• Line loading

• Bottleneck identification

Time study therefore connects shop-floor work measurement with broader production management.

Time & Motion Study for Cost Reduction

Production time has a direct relationship with manufacturing cost.

Reducing unnecessary time and movement can contribute to:

• Lower labour cost

• Better machine utilisation

• Higher output

• Lower overtime

• Lower handling cost

• Better capacity utilisation

• Reduced production losses

The objective is not simply to reduce the time allocated to an operation, but to eliminate unnecessary work and improve the method so that the required work can be completed more efficiently.

Integration with Lean Manufacturing

Time and motion study supports lean manufacturing by providing measurable evidence of process losses.

It can be used alongside:

• 5S

• Standardised work

• Kaizen

• Value stream analysis

• Waste elimination

• Line balancing

• Continuous improvement

• Workplace optimisation

This creates a structured approach in which improvement activities can be measured before and after implementation.

Digital Time & Motion Analysis

Traditional time studies can be strengthened through digital tools and operational systems.

Depending on the requirement, time-study findings can be connected with:

• ERP systems

• PPC systems

• Production monitoring

• Digital dashboards

• MIS reporting

• Production databases

• Digital work instructions

• Performance monitoring systems

Our industrial engineering and IT/ITES capabilities allow time and motion findings to be incorporated into broader production and business management systems.

Applications Across Manufacturing

Time and motion studies can be applied to a wide range of manufacturing activities, including:

• Assembly

• Machining

• Sheet metal processing

• Fabrication

• Welding

• Packaging

• Textile manufacturing

• Plastic processing

• Automotive components

• Electrical and electronic products

• Inspection

• Material handling

• Manual production operations

• Semi-automated processes

The study methodology is adapted to the characteristics and requirements of each operation.

Key Benefits of Time & Motion Study

A structured Time and Motion Study can help organisations achieve:

• Accurate standard times

• Improved productivity

• Reduced cycle time

• Better manpower utilisation

• Improved machine utilisation

• Reduced unnecessary movement

• Better workstation design

• Improved line balancing

• Better capacity planning

• Improved production planning

• Reduced operational costs

• Better performance measurement

• Improved production consistency

• Reduced operator fatigue

• Improved process visibility

Our Time & Motion Study Advantage

Our approach combines industrial engineering expertise with practical manufacturing experience.

With more than 25 years of industrial exposure, we focus on understanding the actual production environment rather than applying theoretical standards without considering operational realities.

Our studies integrate:

• Time study

• Motion study

• Work measurement

• Method study

• Lean manufacturing

• Line balancing

• Productivity improvement

• Capacity analysis

• Process optimisation

• Production planning

• Data-driven performance measurement

This allows time and motion study to become a practical improvement tool rather than simply a measurement exercise.

From Measurement to Improvement

Time and Motion Study is most valuable when measurement leads to action.

Our objective is to move through a structured cycle:

Observe → Measure → Analyse → Improve → Standardise → Monitor

By accurately understanding how work is performed and how much time it requires, organisations can establish better methods, realistic standards and measurable productivity improvements.

We help manufacturing organisations transform shop-floor observations into actionable improvements that support higher productivity, better utilisation, improved capacity and stronger operational performance.

Measure the work. Improve the method. Establish the standard. Increase productivity.

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