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IMPLEMENTATION OF MAYNARD OPERATION SEQUENCE TECHNIQUE

(MOST) TO IMPROVE PRODUCTIVITY AND WORKFLOW – A CASE STUDY

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© 2018 JETIR June 2018, Volume 5, Issue 6 www.jetir.org (ISSN-2349-5162)

IMPLEMENTATION OF MAYNARD
OPERATION SEQUENCE TECHNIQUE
(MOST) TO IMPROVE PRODUCTIVITY AND
WORKFLOW – A CASE STUDY
1
M.S.Rahman,2R.Karim,3J.Mollah,4S.Miah
1
Lecturer,2Assistant Professor,3, 4 Students
1, 2, 3, 4
Department of Industrial and Production Engineering
1,2,3,4
Jessore University of Science and Technology, Jessore- 7408, Bangladesh
________________________________________________________________________________________________________

Abstract: Profit gain is the main goal of a manufacturing industry. The successes of industry depend on its productivity. This
productivity suffers due to the lack of established standard time for activities carried out by operators, the non-value added
activities involved and the unproductive methods, material expenditures, and imbalance in the material flow. This study is
conducted through application of Maynard Operation Sequence Technique (MOST) in the sewing section of a garment industry is
taken into consideration with the aim of identifying the non-value added activities and minimizing the bottlenecks to improve
productivity and reduce product cycle time, production cost per product. Present method reduced the total activity time from 139
seconds to 109 seconds and improved daily productivity from 600 pieces to 1600 pieces .

Keywords- Maynard Operation Sequence Technique (MOST), Bottleneck, Takt time, Improvement of Productivity.
________________________________________________________________________________________________________
I. INTRODUCTION

Non-value added activities are an important factor for any kind of manufacturing industry. Non-value added
activities are those that do not append a value to the product but the authority has to pay. The productivity of
a manufacture company hampers by the bottlenecks workstation. As result the bottleneck workstations and
non-value added activities act as a vital fact to gain the company‟s goal. So it is very essential to identify
and eliminate the bottleneck and non-value added activities. There are various tools and techniques known
as lean tools to identify and eliminate non-value added activities. Among of them “Maynard Operation
Sequence Technique (MOST)” is one of the most common tools. The MOST can be defined as a way of
analyzing the operations or sub-operations performing through several methods, steps and sequences, etc. in
terms of time. In other words, it is a predetermined motion time method that aims to define the standard
time of performing the work.At first, in 1960s H.B. Maynard and Company In introduced MOST but in the
basic form of MOST had started from 1967s in industrial application. Finally, in 1970 the Basic MOST was
modified and named as Clerical MOST to perform the administrative and clerical work in the company.
Bangladesh is well enriched in garments industry. This industry plays a vital role for the economic
development of the country. So it is very important to increase productivity by smooth workflow. For this
research study a garment industry was selected which located in Dhaka, Bangladesh and this industry
produces a lot of garments product and export them. During this study a particular operation area i.e sewing
section of T-shirt fabrication was considered to implement the MOST. Like most of the other, the operator
of this section works as a conventional way. Due to this a lot of non-value added motion of the workers are
exist. The Maynard Operations Sequence Technique (MOST) is implemented for increasing the productivity
by identifying bottleneck, standard time and excess motion of the sewing section.

II. LITERATURE REVIEW

The implementation of MOST in different industries proved its significant contribution to enhance the
productivity. M. Jadhavet al (2017) implemented MOST in Mahindra CIE automotive industry and
increased productivity through reducing product and labor cost [1]. A.A.karad et al (2016) improved the
productivity of an auto company by MOST. They saved takt time 1.90 min and also saved annual
investment 18 lakh [2]. Sunil Londhe (2016), in his study „ Review On Work Measurement By Maynard

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Operation Sequencing Technique‟, The designing, scheduling, estimation of prices and analysis of
performance are used as Work measuring tools for management choices. [3].Ankit P. Vekariya (2015)
implemented MOST in Manufacturing Process of Diesel Engine and carried out a decision that, to increase
productivity and determine standard time for any enterprise Work study is most effective tool.[4]. Jamil et
al. (2013) integrated MOST with the Ergonomics study, this integration helps to optimize the standard times
of the process activities and reduce the fatigue of the workers simultaneously. As a result, the workforces
gained a better working environment while they performed their activities with a comfort manner
consequently the rate of productivity also increased.[5]. Yadhav in his study optimize the Manpower
through implementing MOST. In his study, it was found that MOST enables a better picture of working
procedures and thus leads to the elimination of Nonvalue-added operations. It was observed that the work
content utilization factor was very less and a considerable amount of manpower remained unutilized. He
suggested balancing workload by assigning more work and improving productivity by using MOST.[6].
Belokar et al (2012) implemented MOST to increase the efficiency and the cost-effectiveness of the work
and reduce worker‟s fatigue through identification and minimization of the Non- Value Added (NVA)
activities. As a result of their study, the authors managed to save 18% of the working time and define a new
set of reduced standard time.[7]. Similarly, Gupta and Chandrawat (2012) applied the basic MOST in a
small Indian industry and showed possible and significant improvement in the productivity. [8]. Abdullah
and Bahiyah(2011), in their study, Labor Utilization and Man to Machine Ratio study at a Semiconductor
facility, attempted to improve productivity and reduce operational cost in MNC semiconductor industry
using Maynard Operation Sequence technique (MOST).[9]. Mahajan (2011), examined the reduction in tool
changeover time by the implementation of Single Minute Exchange of Dies (SMED) through MOST for
Legrand (India) Pvt. Ltd, Jalgaon. He reviewed MOST technique and compared it with traditional time
study application method.. He concluded that by application of other MOST methods tool changeover time
can be further reduced into single digit minutes.[10]. Productivity Improvement through Application of
MOST in Switchgear Company was studied by Sir Deshmukh et al (2009). Predetermined Motion Time
systems (PMTS) have become attractive and a useful evaluation tool for manpower utilization and
productivity improvement [11].

III. METHODOLOGY

By analyzing the undertaken case of sewing section in a garment, several problems have been identified
including the improper capacity planning. The non-value added activities were increased and affected the
whole assembly line due to the absence of pre-defined standard time, working methods, unplanned working
distance, and animbalance in the material flow etc.. Hence, the competitive advantages in the undertaken
sewing line can be brought into thesystem by the proper use and selection of body motion, balancing
workflow and optimizing layout body motion of the operator. Hence, to increase the line efficiency as well
as the production rate of the undertaken case study, the MOST technique is implemented for identifying the
bottlenecks and NVA added activities of the production line as well as setting time standard. The basic
MOST technique constitutes with the general move, control move and tool use process. In sewing section
for sewing cloth, only general moves exist. For that reason, we studied only with the general move or
motion of the sewing operator.

3.1. General Move:

In the General Move Sequence Model the studied object moves freely in the air. In brief, the General Move
model follows the Sequence of GET, PUT, and RETURN i.e. |A B G|, |A B P|, and |A|. Where, A = action
distance, B = Body motion, G = Gain control, P = Placement. Each of these parameters A, B, G, and P has
its own index value which is determined from the MOST Data Card. The General Move Sequence Model is
ABG ABP A

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Action Distance (A):

This parameter is used to analyze all spatial movement or actions of the fingers, hands, and/or feet. The
index value of action distance using in this paper is described in table -1.

Body Motion (B):

This parameter is used to analyze either vertical motions of the body or the actions necessary to overcome
an obstruction or impairment to body movement. In sewing section to sewing, there is no use of body
motion. For sequence maintaining, we only use B0 as body motion index value.

Gain Control (G):

This parameter is used to analyze all manual motions employed to obtain complete manual control of
objects and to subsequently relinquish that control. The using index value of thegain control is given table-1.

Placement (P):

This parameter is used to analyze actions at the final stage of an object‟s displacement to align, orient,
and/or engage the object with another object(s) before control of the object is relinquished. The using
placement index value is given table-1.

Table-1: Parameters Index Value.

Parameter Index value When using
A0 This is any displacement of the fingers, hands, and/or feet a distance
of 2 inches or less.
A1 Actions that are confined to an area described by the arc of the
A outstretched arm pivoted about the shoulder.

A3 The trunk of the body is shifted or displaced by walking, stepping to

the side, or turning the body around using 1 or 2 steps.
B B0 No motion of body
G0 No requiring of controlling the object.
G G1 Gain control of an object by grasping it as long as no difficulty is
encountered.
G3 While one hand is grasping an object, the other hand must wait before
it can grasp the other object.
P0 This is “placement” in which no placement occurs. The object is
P picked up and
P1 The object is placed in appropriate locations with no apparent
aligning or adjusting motions.

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3.2 Time Unit used in MOST:

The time measurement unit (TMU) is used as a time unit for MOST analysis, which is converted to the
minute by using the following Table-2
Table -2: Unit Conversion Table
1 TMU = 0.00001 hour 1 hour = 100000 TMU
1 TMU = 0.0006 minute 1 minute = 1667 TMU
1 TMU = 0.036 second 1 second = 27.8TMU

3.3 Procedures of MOST calculation:

A typical MOST work sequence code would look like this:

A10 B6 G3 A6 P3 A0

Step – 1 adds up all the subscript numbers

10+6+3+6+3+0= 28 (the subscript is the MOST index value)

Step – 2 multiple the sum of the index by 10.

This answer gives the TMU equivalent
28 x 10 = 280 TMU

Step – 3 Convert to time in seconds

280U *0.036 seconds = 10.08 seconds

IV. CASE STUDY

For this study, the sewing section of selected industry consists of eight workstations. To show the process of
data extraction in line the MOST analysis, a short explanationthrough sequential workstation 1 to
workstation 8 is shown in table-2.

Table-2: data extraction process

SL Method description Index value Move

1 Pick up cloth A3 B0 G1 A1 B0 P0 General move

2 Placing the cloth A0 B0 G3 A3 B0 P1 General move

3 Matching front & A0 B0 G3 A0 B0 P0 General move

back part

4 Matching the cloth A3 B0 G3 A0 B0 P0 General move

The selected sewing section consists of eight workstations. Time calculated for the existing production
section carried out by applying MOST technique. Time calculated for each workstation individually. The
elemental activity times as measured for the current workstation as shown in table – 3

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Table – 3: Estimated activity time for the current operation in the workstations

WORK STATION - 1 WORKSTATION -2

Activities Time in Time Activities Time in Time
(TMU) in (TMU) in
(sec) (sec)
Picking & placing the 112 4 Picking &placing the cloth on 56 2
cloth on machine machine
Collar joining with body 167 6 Neck support joining with 250 9
sewing collar
Placing the cloth to store 56 2
Total completion time 335 12 Total completion time 306 11

WORKSTATION - 3 WORKSTATION - 4

Picking &placing the cloth 83 3 Picking &placing the cloth on 56 2

on machine machine
Sleeve hem 196 7 Left sleeve joining with body 139 5
part
Placing the cloth to store 28 1 Changing side 56 2
306 11 Joining right sleeve with body 140 5
Total completion time part
Placing the cloth to store 28 1
Total completion time 419 15
WORKSTATION – 5 WORKSTATION - 6
Picking &placing the cloth 112 4 Picking &placing the cloth on 139 5
on machine machine
Joining right side 444 16 Left sleeve tuck 83 3
Changing side 250 9 Right sleeve tuck 83 3
Left side joining 500 18 Placing the cloth to store 28 1
Placing the cloth to store 28 1 Total completion time 333 12
Total completion time 1334 48
WORKSTATION – 7 WORKSTATION- 8
Picking &placing the cloth 112 4 Picking &placing the cloth on 112 4
on machine machine
Top stitch joining 250 9 Body hem 250 11
Placing the cloth to store 56 2 Placing the cloth to store 56 2
Total completion time 418 15 Total completion time 418 15

In-order to identify the bottleneck workstations of the selected sewing section, the total completion time for
each station found from the MOST technique are shown in table – 4.

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Table-4: Summary of existing time for Workstations.

Workstation No Completion in MTU Completion Time in second
Workstation - 1 335 12
Workstation – 2 306 11
Workstation – 3 306 11
Workstation – 4 419 15
Workstation – 5 1334 48
Workstation – 6 333 12
Workstation - 7 418 15
Workstation - 8 418 15
Total 3869 139

60
48
50
40
Time in Sec

30
20 12 15 12 15 15
11 11
10
0

Fig. 1: Existing time for Workstation

As shown in above fig.1, workstation – 5 required maximum time to complete work. So the workstation – 5
is identified as a bottleneck workstation which requiring a cycle time 48 second. To be competitive
advantages, at first necessary step is needed to reduce cycle time of bottleneck workstation by incorporation
of positive changes. Implementing MOST technique, process flow working procedure (called standard
operating procedure (SOP)) and the cycle time of a workstation can be reduced. To reduce the cycle time of
bottleneck workstation, replaced the operator with a skilled operator. In this way, production flow smoothly.

Table – 5: Proposed solution for workstation - 5

Activities Activity time in seconds Activity time in seconds

(By Existing worker) (By new skilled worker)
Picking &placing the cloth on 4 2
machine
Joining right side 16 9
Changing side 9 5
Left side joining 1 1
Placing the cloth to store 1 1
Total time in seconds 48 18

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Table –6: Proposed change the worker and its effects.

Workstation No Completion in MTU Completion Time in second

Workstation - 1 335 12
Workstation – 2 306 11
Workstation – 3 306 11
Workstation – 4 419 15
Workstation – 5 500 18
Workstation – 6 333 12
Workstation - 7 418 15
Workstation - 8 418 15
Total 3035 109

20 18
15 15 15
Time in sec

15 12 11 11 12
10
5
0

Fig.2: proposed cycle time

As shown in fig.2, changing the operator at workstation – 5 required bottleneck time is minimized. Time
minimized for bottleneck workstation- 5 means line is more balanced than before implementing of MOST
technique.

V. RESULT AND DISCUSSION

In this study, it was found that before implementation of MOST technique in selected garment industry to
complete a basic T – shirt time consumed 139 seconds. But, after implementation of MOST bottleneck
time reduced and 109 seconds is needed to complete the same T – shirt.After identifying bottleneck and
improving the method of working motion time reduced 40 seconds. To measure the production rate, the
Takt time of the selected sewing line is estimated by dividing the total available time with the customer
demand. The Takt (cycle time per work station) time and productivity as per demand are shown in table-
6.

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Table -6: Takt time and daily productivity
Available
working Before MOST implementation After MOST implementation
time/day
(sec)

Productivity

Productivity

demand(pc)
per day(pc)

per day(pc)
Bottleneck

Bottleneck
time (sec)

time (sec)
time(sec)
time(sec)

time(sec)

time(sec)
activity

activity

Daily
Total

Total
Takt

Takt
28800
139 48 18.1 600 109 18 18.1 1600 1590

Here,
Takt time = Available working time÷ Daily demand

20
18
16
Time in secs

14
12
10
8
6
4
2
0
W/s. 1 W/s.2 W/s.3 W/s. 4 W/s. 5 W/s.6 W/s.7 W/s.8
Takt time 18.1 18.1 18.1 18.1 18.1 18.1 18.1 18.1
Completion Time 12 11 11 15 18 12 15 15

Fig.3: Takt time

As the estimated Takt time for the sewing section is as 18.1 sec per piece and daily demand is 1590 pieces
which not to be diverted by new practice. So, the new proposed changes in workstation – 5 it is possible to
maintain the daily demand as well as improve the productivity.

VI. CONCLUSION:

In this studes, tried our best to find a possible solution for exists problem in the selected garment sewing
section by applying MOST technique. It is said that, the Maynard operation sequence technique plays a vital
role to identify and eliminate bottleneck workstation and to make a competitive industrial environment.
MOST also helps to improve the productivity of a manufacturing company by reducing non-value added
activities. By implementing MOST, it is possible to proper utilization of total available time and to save
money.

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VII. REFERRENCE
[1]. MangeshJadhav, SamadhanMungase, Prof. A. A. Karad (2017), “Productivity Improvement through
Maynard Operation Sequence Technique” International Journal of Scientific Research in Science,
Engineering and Technology ,volume-3, issue-1, [(3)1: 565-568]

[2] Prof. A. A. Karad1, Mr. Nikhil K. Waychale2, Mr. Nitesh G. Tidke3,(2016), “Productivity Improvement
By Maynard Operation Sequence Technique” International Journal of Engineering Research and
General Science Volume 4, Issue 2

[3].Sunil Londhe,(2016) „Review of Work Measurement By MOST‟, IJATES, Volume 4, Issue 3, March
2016,PP. 563-569.
[4].AniketP. Vekariya,(2015) „Productivity Improvement Of Manufacturing Process Of Diesel Engine By
Time And Motion Study Method (MOST Technique)‟, IJAERD, Volume 2, Issue 6, PP.577-584.

[5].Jamil, M. G., Saxena, A., and MrVivekAgnihotri, M.,(2013) “Optimization of Productivity by Work
Force Management through Ergonomics and Standardization of Process Activities using MOST Analysis-A
Case Study”, Global Journal of Researches In Engineering, vol.13, no.6,

[6]. Yadav T.K.,(2013) Measurement Time Method for Engine Assembly Line with Help of Maynard
Operating Sequencing Technique (MOST), International Journal Of Innovations In Engineering And
Technology (IJIET), vol. 2,no.2

[7]. Belokar, R. M., Dhull, Y., Nain, S., and Nain, S.(2012), Optimization of Time by Elimination of
Unproductive Activities through „MOST‟, International Journal of Innovative Technology and Exploring
Engineering (IJITEE), Vol. 1, no. 1, pp. 77-80

[8]. Gupta, M. P. K., and Chandrawat, M. S. S.,(2012),“To improve work force productivity in a medium
size manufacturing enterprise by MOST Technique”, IOSR Journal of Engineering (IOSRJEN), Vol. 2,
no.10, pp. 08-15

[9]. Abdullah Rohana and Bahiyah Aida, 2011, “Labor Utilization and Man to Machine Ratio Study at a
Semiconductor Facility”, Journal of Engineering and Technology, Vol.2, ISSN 2180-3811, PP.75-84.

[10].MahajanHarshal V.,2010-2011, “A Project Report on Reduction in Tool Changeover Time by SMED

through MOST for Legrand (India) Pvt. Ltd”, MIDC, Jalgaon, A project report (MBA), Institute of
Management and Research, Jalgaon

[11]. SirdeshmukhNeelesh P.C, Puri Y.M, Chopde I.K and Pundlik A.D (2009), “Productivity Improvement
through Application of MOST in Switchgear Company”, Productivity. Vol.50, No.2, July -September,
PP.146-151.

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