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SYNOPSIS
MOST is an acronym for Maynard Operation Sequence Technique. MOST is an activity based
work measurement system that enables you to calculate the length of time required to perform a
task i.e. a system to measure work. In this case it is used to calculate the length of time required
for the fixture to bond the body panel into a car assembly.
This technique is based on fundamental statistical principles and basic work measurement data
compiled over many years. MOST concentrates on movement of objects. It was noticed that the
movement of objects follow certain consistently repeating patterns, such as reach, grasp, move &
position of object. These patterns were identified and arranged as a sequence events followed in
moving an object. This concept provides the basis for the MOST Sequence models.
This technique helps in benchmarking the methods & activities followed in various operations in
the industry with world class standards. It eliminates the subjective performance rating and has a
much better acceptance of workmen/unions because it is totally transparent & easy to
demonstrate.
More specifically, MOST is used to:
1. Break down the operation/process into smaller steps/units.
2. Analyze the motions in each step/unit by using a standard MOST method sequence.
3. Assign indices to the parameters constituting the method sequence for each task.
4. Sum up the indices to arrive at a time value for each step/unit.
5. Sum up the time values for all the steps/units to arrive at the normal time required to perform
that operation/process.
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CHAPTER 1
INTRODUCTION
Fundamental premise behind Productivity improvement as per Japanese philosophy is Withoutmeasurement there cannot be any improvement.
One of the most scientific techniques of work measurement discovered by H. B. Maynard & Co.
Pittsburgh in 1970 is M.O.S.T. The Maynard Operation Sequence Technique, MOST, including
Basic, Mini and Maxi versions, makes the measurement of work more practical, efficient, and
inexpensive task for the industrial engineer.
A powerful analytical tool that helps increase productivity, improve methods, facilitate planning,
establish workloads, estimate labor costs, improve safety, and maximize resources, MOST can
be applied to any type of work for which a method can be defined and described. MOST has
become the standard for thousands of companies in a broad range of industries.
Fast, economical, accurate, consistent, and easy to learn, MOST eliminates the need for
inefficient stopwatch studies in the development of realistic and reliable work/time standards.
Instead, through a unique and highly efficient procedure, MOST generates these standards as a
by-product of the work center layout the method description. In turn, these standards provide an
accurate and consistent database for costing, planning, processing, scheduling, line balancing,
incentive wage payment, and performance evaluation systems.
1.1 Maynard Operation Sequence Technique [MOST]
Mini MOST for highly repetitive and Short Cycle Operations (2 Minutes or less)
Basic MOST for General and medium Cycle Operations
Maxi MOST for Non repetitive Long Cycle Operations
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1.2 Advantages of MOST
Streamlines operations and quickly identifies inefficient methods.
Provides consistent standards and accuracy to within 5% with a 95% confidence level.
Timings can be obtained in advance before actual start of production.
Reduces the time required for data development and standard setting.
Can be applied to any method-defined manual work.
1.3 METHODOLOGY
Top Down Standard Data Approach is used in MOST Work Measurement, which helps to
minimize the number of Standard Data Elements (Sub Operations) and applies the Standard Data
to create time standards efficiently and accurately.
1.4 MORAL Cycle
M: Mapping O: Observation R: Record using MDAT A: Analysis L: Lean optimization
Process Mapping of entire plant is done with up front planning and total involvement of the
employees and domain experts. Necessary Sub Operations used to cover all Operations are
defined. Activities are Observed or visualized. MDAT [M.O.S.T Data Acquisition Tool] is used
for Recording Operations method steps with linkage to Process Sheets. Using this Database,
MDAT can provide various Analysis and reports for us to Lean and optimize.
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1.5 Sequence Models
1.6 MOST Study Form
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1.7 MOST ANALYSIS
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CHAPTER 2
LITERATURE REVIEW
2.1 MOST Application for Labor Productivity Improvement
The purpose of this work done by Norashikin Binti Rahman[1] presents that Productivity is
the most important thing in the manufacturing world. Generally, this study is about work study
for labor productivity improvement utilizing Process Mapping and Maynard Operation Sequence
Technique (MOST). Work study in productivity improvement could be done in two approaches;
which are method study and time study. Thus, this research will use process mapping as the
method study and Maynard Operation Sequence Technique (MOST) as the time study method.
The aim for this research is to identify opportunities for improvement to current production
system by performing work study on the manual operators activities, determining current
operators utilization as well as establish standard time for manual process. All this initiated by
performing work study on the manual operators activities. From this study, the standard time,
utilization and recommendation for man power planning could be established. These results
could be used for improving the labor productivity at the company.
The purpose of this work done by A. Abduelmula and C. Wagner [2] presents the methodology
to design, evaluate and manage a lean manufacturing system at Visteon Corporation. The
methodology aims at developing a management strategy to optimize the use of manufacturing
technology. First, several lean cells have been proposed and each cell is studied in details.
Maynard Operation Sequence Technique (MOST) is used to determine the cycle time of each
activity. Second, each cell is simulated using Simul8 simulation software. The simulation model
uses throughput, labor productivity, and work-in-process measure of performances. The
simulation model is run for 40 hours and the results showed the superiority of the lean
manufacturing system over the existing traditional manufacturing system. The lean systemshowed 35% decrease in labor, and 30% decrease in scrap over the existing traditional cell. The
model can also be used by the management team for continuous improvement process of the
system to optimize manufacturing technology utilization, increase throughput, identify
bottlenecks and work-in-process, and identify machine and labor utilization.
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2.2. Product Costing Based On Standard Time Estimation
The purpose of this work done by Jianxin Jiao and Mitchell M. Tseng [3] proposes a
pragmatic approach to product costing. The approach involves two stages, namely the
preparatory stage and the production stage. In the preparatory stage, standard routings are first
extracted from existing products. A generic activity hierarchy is established according to the
analysis of standard routings, where cost drivers for each activity are identified and summarized
by appropriate Cost-related Design Features (CDFs). Then the Maynard Operation Sequence
Technique (MOST) is employed to analyze each operation of standard routings to determine the
associated standard time. Historical cost data are analyzed to induce the relationships between
the CDFs and standard time, namely Time-Estimating Relationships (TERs). By allocating plant-
wide overhead costs to standard routings, the unit price of standard time is established to indicate
Cost-Estimating Relationships (CERs). A library of material costs is also summarized from
existing products. In the production stage, CDFs are first induced from the schematic of a new
design. Then a Dummy Process Plan for this design can be inferred and used to retrieve the
associated TERs to determine its time estimate. Once a standard time has been estimated, CERs
can be applied to compile the total product cost by adding the estimated material costs.
Standards routings provide a basis for estimating time requirements based on historical data. Theactivity hierarchy helps to trace the underlying activities that drive costs and identify cost related
design features that enable rapid product costing. The allocation of plant-wide overhead costs to
the manufacturing indirect cost pool facilitates total product cost estimation. The discrimination
of TERs and CERs not only alleviates the difficulty in cost function approximation, but also
simplifies the considerations of volume ranges, distributed manufacturing plants and so on.
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2.3. Lean Enterprise the MOST Way in Industries
The purpose of this work done by Mr. Milind More and Mr. Sujit Bhosale [4] proposes the
idea of observing the things critically by going to the News Paper Printing Plant. Considering
this we have observed & analyzed each operation critically, written down the MOST Elements of
the given operation & uploaded the same along with parameter indexing. We concentrated on the
methods improvement, eliminating the non-value added activities, reducing the operating motion
losses in the given operation. The movements/ motions have been studied from the Ergonomics
point of view. After standardizing the operations on respective lines we concluded that common sub-
operations can be used to study respective operations. Sub-operations are basically repetitive activities in
given operation activities. We dwelled on this & prepared common sub-operations for packing, inspection
operations. With the help of these common sub-operations, Operations were prepared with
MDAT software. As per the already defined process flow/ VSM, the operations were linked
against the respective routing code. The cycle time & work content at each level i.e. element
level, sub-operation, operation, routing was be used to do further analysis.
The purpose of this work done by Mr.Ashok Badve and Mr. Amol Mate[5] proposes the idea
of observing the things critically by going to the Cement Industry. To measure the work content
of the work force in the plant using MOST in production direct, indirect and office areas. A total
of approximately 1300 associates were studied during this study. After work content was
established, the lines were balanced to improve the engagement time of the work force from its
current level and proposed manpower to be deployed was calculated. Activities performed in the
PRODUCTION and NON-PRODUCTION departments for the following processes were
considered in scope of work.
Production Run time activities performed by the direct and indirect associates on theequipment installed in various processes
Preventive Mechanical Maintenance related activities Instrumentation Maintenance related activities Quality Control related activities
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The purpose of this work done by Mr.Ashok Badve and Mr. Amol Mate[6] proposes the idea
of observing the things critically by going to the Tyre Manufacturing Industry. To measure the
work content of the current work force in the plant using MOST in production direct and indirect
areas. More than 300 associates (direct and in-direct areas) were studied during this study. After
work content was established, the lines were balanced to improve the engagement time of the
work force from its current level and proposed manpower to be deployed was calculated.
Activities performed in the PRODUCTION departments for the following processes were
considered in scope of work.
The purpose of this work done by Mr. Ashok Badve [7] proposes the idea of observing the
things critically by going to the Foundry Industry. LeMW projects have been successfully
completed in Aluminum and Cast Iron foundries mostly in Maharashtra. We have covered
LPDC, GDC and manual pouring processes so far. Typical foundry processes covered during the
project are:
All the foundry clients achieved more than 38% increase in labor productivity after LeMW
implementation. Multi Machine Balancing was typically achieved for the following processes: Molding, Core Making were balanced with 2 machines per person LPDC & GDC Machines were balanced with 2 machines per person Furnace, pouring into ladle and Knockout/Fettling activities were balanced up to some
extent and Shot blasting and Inspection were balanced with one operator.
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CONCLUSIONS
During the 1950s and 1960s, the work measurement field became inflated with conventional
derivatives of the original MTM [Methods time Measurement]system (MTM-1) first publishedin 1948. That trend has continued to some extent with one exception: MOST. In the mid-1960s, a
new approach, a more practical and user-friendly method (and perhaps more important, a faster,
simpler, and more cost-effective technique) was necessary to maintain a high level of interest in
work measurement. MOST seems to have been the answer. Over 30,000 people representing
more than 4000 organizations have become certified MOST users. MOST has been translated
into at least 15 languages and is in use in more than 35 countries around the world. MOST
satisfies all the criteria of simplicity, speed, accuracy, consistency, applicability, integrity, and
universality that can be expected from a modern work measurement technique and system.
MOST for Windows represents the state of the art in the area of computerized work
measurement, and users enthusiastically endorse and support MOST.
In search of accuracy, consistency, and speed, predetermined motion time systems were first
being starting with motion time analysis (MTA). Methods time measurement (MTM) became the
foundation for many simplified and more efficient techniques.
As with any measurement, the measurement of work brings knowledge. Through this
knowledge, factual decisions and improvements can be made and could be exercised. Work
measurement has for a long time been a sound management tool to be used as a basis for
planning and scheduling, estimation of costs, and evaluation of performance. In essence,
managers are looking at work measurement as a means to satisfy their desire and need to know,
and predict with confidence.
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SUMMARY
During the past 10 years, the work measurement and standard setting procedures have become
simpler, faster, and more integrated with other functions to attract the attention they deserve.
Manual MOST and MOST for Windows have proven to meet those criteria. Todays computer
technology has reached a level that cannot be ignored by work measurement specialists. By
taking advantage of this technology, time standards could and should become a logical and
integral part of any business system as is the case in many companies already. This general trend
in industry is automation. Therefore, it is obvious that we will see fully automated procedures
(i.e., Auto MOST) for calculating and updating time standards based on data developed and
maintained by industrial engineers. To achieve these goals it will be necessary to stimulate the
employees both in industry and services, to adopt a positive attitude toward a fundamental and
widely used industrial engineering discipline: theMeasurement of Work.
Work measurement: The science that brings more and better knowledge to people about work
and how to improve work. Hence M.O.S.T technique,
Enables you to analyze any type of manual work with one of the most efficient and widely used
work measurement techniques.
Reduces the time needed to analyze work as MOST can be applied in a fraction of the time it
takes to perform traditional time study or other predetermined motion time systems.
Provides you with a tool that is method sensitive where the outcome of the analysis provides
cues as to where there are opportunities for saving time, money and energy.
Eliminates the subjectivity involved in performance rating an activity since the MOST
technique is based on a 100% pace.
Meets the needs of many industries such as manufacturing, service and distribution and is well
accepted by employees, unions and management.
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REFERENCES
[1]. Norashikin Binti Rahman, [April 2007], Work Study for Labor Productivity Improvement
Utilizing Process Mapping and MOST. Faculty of Manufacturing Engineering, UniversitiTeknikal Melaka, Malaysia.
[2]. A. Abduelmula and C. Wagner, [2004]. Design and Evaluation of Lean Manufacturing Cells:
A Simulation Model.Industrial Engineering Department, Visteon Corporation, Sterling Heights,
Michigan 48310, USA.
[3]. Jianxin Jiao and Mitchell M. Tseng, [1997]. A Pragmatic Approach to Product Costing
Based on Standard Time Estimation, The Hong Kong University of Science and Technology,
Kowloon, Hong Kong.
[4]. Mr. Milind More and Mr. Sujit Bhosale[13 Nov to 3 Dec. 07]. Lean Enterprise the MostWay at News Paper Printing Plant. Regular Printing Press. Maintenance of all machines.
[5]. Ashok Badve and Amol Mate [23/11/2009] Lean Enterprise MOST Way in Cement
Industry: A Case Study on Work Force Productivity Improvement. UMAS Private Limited.
India.
[6]. Ashok Badve and Amol Mate [15/5/2010]. Lean Enterprise MOST Way in Tyre
Manufacturing Industry: A Case Study on Process Improvement, Facility Layout Planning and
Work Force Productivity Improvement. UMAS Private Limited. India.
[7]. Ashok Badve, Managing Director [22/10/2009]. Lean Enterprise MOST Way in Foundry
Industry. UMAS Private Limited. India.
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