Why ERGO-MTM

www.pwc.com
Integration of MTM and
Ergonomics in
Industrial Practice
1st International Conference on Ergonomic
Assessment in Industrial Practice
ERGO-MTM model
ERGO-MTM is
a Worl Class
Manufacturing
& Logistics
tool
PwC Advisory
The new way to design efficient and safe
processes
Why ERGO-MTM
Work measurement and task assignment
require the use of predetermined time
systems and the control of biomechanical
load to design and implement efficient and
safe working systems
Industrial engineers have a huge
responsibility when designing and
optimizing technological systems
We cannot afford to separate process
efficiency from ergonomics: it would be too
expensive
Synergies make the cost of ergo
analysis represent only a small
percentage of the cost to take care of
professional diseases caused by
biomechanical overload (absenteeism, low
performance, social costs, etc.)
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 3
What is Ergo-MTM
Ergo-MTM is a best practice for the calculation of
a fair standard time of a manual task
It represents the joint application of the most advanced
techniques in the fields of predetermined time systems and
ergonomic workload calculation
• Based on the most widespread work measurement
technique (MTM)
• Based on a holistic ergonomic assessment method
(EAWS)
• Integrates work content and ergonomic work load in an
engineered way through the Ergo-MTM model for Rest
Allowance Calculation
• Focused on process design / redesign
• Appreciated by the unions
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 4
Work Content and Work Load Definition
Ergo-MTM procedure steps
Work Content Calc.
• Through MTM analysis of
manual tasks
MTM
1
Ergonomic Risk Def.
• Through EAWS risk
assessment for the Whole
Body & Upper Limbs
EAWS
2
Rest Factor Calculation
• Through the application of
the Ergo-MTM Model
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
Risk Score
Ergo – MTM
3
Workload Calc.
• For every process flow,
calculation of assembly times
with respect of ergonomics
Basic Times
Ergonomic Allowance
Ergo – Balancing
4
Standard Times
2.12.2011
Slide 5
Ergo-MTM workflow
4
Standard Time/Takt + work organization
Apply Ergo-UAS Model
3
Allowance Time
ALLOWANCE
FACTOR
60%
Ergo Allowance %
55%
50%
52,0% 52,0% 52,0% 52,0% 52,0% 52,0% 52,0%
45,0%
45%
38,5%
40%
35%
32,5%
30%
27,0%
25%
EAWS risk score
22,0%
20%
17,5%
13,5%
15%
10,0%
10%
7,0%
4,5%
5%
1,0%
2,5%
0%
WP 2
WP 3
WP 4
Basic Time
WP 1
1
WP 2
WP 3
MTM analysis of work content
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
WP 4
WORKING METHODS
WP 1
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
0
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
BIOMECHANICAL LOAD
EAWS
(Ergonomic Analysis
Analysis))
2
EAWS analysis of work load
2.12.2011
Slide 6
What is MTM
Methods-Time Measurement
MTM is a work design technique
which assigns a manual task a
normalized time based on a
standard level of performance
MTM is a set of techniques
designed to measure manual
work properly in different fields
of application (from mass
production to job shop)
Design or observe
the work process
Identify the basic
motions
Determine the
influencing factors
Manual fastening
Get and place
screw, search for
thread and
execute 3
manual screwing
motions.
Distance < 50 cm
Code
TMU
AF 2
65
ZA1
5
ZB1
10 X 2
TOT
90
Time is based on a
norm performance
(100 MTM)
Basic Time
Calculation
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 7
One MTM system for each field of application
Method level
Work org level
Task
Mass
(MTM-1/MTM-2)
Task
Batch
(UAS
UAS)
One-of-a-kind
(MEK
MEK)
Task
Hedge against method deviations
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
Operator’ s
specialization level
2.12.2011
Slide 8
MTM system dissemination
UAS is the most used MTM system for direct application
Number of MTM certificates issued in the period 2005-2010
NMTMA
UK
MTM-1
MTM-2
SAM
UAS
MEK
EAWS
(fonte IMD Administration)
EAWS
1%
Total
8
52
0
98
0
0
158
Austria
164
2
0
112
102
0
380
France
257
791
0
190
0
0
1.238
4.223
102
0
3.276
970
32
8.603
Italy
54
51
15
399
30
92
641
South Africa
25
4
0
37
0
0
66
172
500
0
176
25
0
873
Germany
Spain
Nordic countries
4
2
650
5
0
0
661
17
0
0
71
11
0
99
USA
241
2
0
340
7
0
590
Brasil
200
1
0
270
36
0
507
Czech
349
28
0
241
23
0
641
Poland
310
9
0
175
44
0
538
Serbia
0
0
18
0
0
0
18
6.024
1.544
683
5.390
1.248
124
15.013
Switzerland
Total
MEK
8%
* MTM-1
40%
UAS
36%
SAM
5%
MTM-2
10%
* MTM-1 is delivered mainly for training
purpose and rarely for direct application
• Official MTM systems are owned and controlled by the International MTM Directorate
• MTM systems are spread and protected by the National MTM Associations
• MTM qualifications and certifications are ruled by the IMD and by the national qualification procedures
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 9
Basic Time is based on a norm performance level
The use of a predetermined time system
like MTM (Methods-Time Measurement)
makes the performance rating unnecessary,
eliminating a large degree of subjectivity,
since all the basic motions (e.g. reach,
grasp, move, etc.) have been measured and
are by definition built upon the normal
level of performance (named MTM normal
performance).
From recent studies conducted to develop
the ergonomic screening system ‘European
Assembly Work-Sheet’ (EAWS), the MTM
normal performance results to be in line
with the most recent ergonomic standards
related to the biomechanical load.
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
MTM
BSI
BEDAUX
95,2
100,0
105,7
120,5
150,6
79,0
83,0
87,7
100,0
125,0
63,2
66,4
70,2
80,0
100,0
British Standard BS3138 gives a comparison of the BSI
scale with the Bedaux Scale which gives BSI = Bedaux x
1.25. Another often quoted figure for the BSI rating scale is
that MTM 100 = 83 on the BSI scale.
2.12.2011
Slide 10
MTM norm performance (100)
PERFORMANCE RATING
Introduction movies
for calibration of 100-% MTM performance
Film no. 69
9-pictures movie with same operation but different performances
135
128
117
106
100
92
84
75
69
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 11
Risk analysis
Norm MTM performance
UAS code: AA2 = 35 TMU = 1,26 s
Frequency = 47,6 act/min
Duration of rep. tasks = 7,2 hrs (430’)
EAWS4 score = 7 ,0* 7,2 = 50 (UL)
0-25 points
Green
26-50 points
Yellow
>50 points
Red
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
First Time Right principle: design the work
organization and measure the workload in the
earliest stages of the process development
2.12.2011
Slide 12
What is EAWS
EAWS Ergonomic
Assessment
Work-Sheet
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
EAWS is a 1st level risk assessment method for
biomechanical load
It offers compliance with the relevant CEN/ISO
standards
Structured to exploit at best the information
available in the MTM analysis to support cycle
description and risk evaluation
It’s an holistic system (full coverage of all risk
areas)
It provides detailed results in 4 sections:
• Body Postures
• Action Forces
• Manual Materials Handling
• Upper Limbs
2.12.2011
Slide 13
EAWS and ERGO-MTM – Main European Users
Company
Tool name
Status
OPEL/GME
Porsche
Daimler
Bosch
Bosch Rexroth
Audi
Karman
Smart
MAN
FGA
IVECO
FPT
VW
Denso T-S
Lamborghini
Beretta Armi
Chrysler
VM Motori
SEAT
NPW
DesignCheck
EAB
BkB, EAWS
EAWS
APSA
AAWS
EAWS
AAWS Cargo
EAWS
EAWS
EAWS
EAWS
EAWS
EAWS
EAWS
EAWS
EAWS
EAWS
Implemented in 1997
Implemented in 1998
Implemented in 2000
Implemented in 2005
Implementation in progress (ITA)
Implemented in 2006
Implemented in 2007
Implemented in 2008
Development in progress
Implemented in 2008
Spain implemented in 2010-11
In progress
Implementation in progress
Implemented in 2008
Implemented in 2010
Implemented in 2010
Implementation in progress
Implementation in progress
Implementation in progress
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
ERGO-MTM
N
N
N
N
N
N
N
N
N
Y
Y
Y
N
N
N
Y
Y
Y
N
2.12.2011
Slide 14
What is the Ergonomic Allowance
Ergonomic
Allowance
Factor
The allowances are thought to compensate for fatigue and
delays at work. Industrial Engineering (IE) practice
distinguishes between constant and variable allowances:
 Constant allowance
•
personal needs (e.g. time for the restroom)
•
basic fatigue
 Variable allowance
•
body postures
•
Forces
•
Loads
•
Repetitive movements of the upper limbs
Fatigue allowances have not reached the state where their
qualifications are completely based on sound, rational
theories. Consequently, next to performance rating, the
fatigue allowance is the least defensible and the most open
to argument of all the factors making up a time standard.
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 15
ERGO-MTM model to quantify the
ergonomic allowance
Ergonomic
Allowance
Factor
The Ergo-MTM Allowance is set to assign the
proper recovery periods
It’s calculated on the basic time
It follows an exponential function driven by the
Ergonomic Load (EAWS risk score)
It’s sized with the objective to assign to red
workplaces enough recovery time to exit from
the red risk area
It links analytically the ergonomic risk with
production costs making ergonomic
improvement investments easier to justify also
from an economical point of view
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 16
ERGO-MTM advantages
 Link with relevant ISO/CEN standards in measuring the
phisical load (mainly CEN 1005 and ISO 11226, 11228)
 Objective motion identification through the link with the MTM
language (easy to identify and count actions)
 Normalized motion frequency calculation based on MTM basic
times (action frequencies are not influenced by the operator actual
performance)
 Data consistency granted by the link with work cycles (if a work
method or a piece of equipment is modified, than the workload is
automatically updated)
 Integration of two job profiles (method engineer and
ergonomist) into one (ergo-engineer) with ensuing cost savings
 Focus on work method as a means to improve productivity and
ergonomic conditions
 Easier to justify investems in ergonomic improvement projects,
since product cost is linked with the phisical workload level (higher
load results in higher fatigue allowance)
ERGO-MTM MODEL – G. CARAGNANO
PwC Advisory
2.12.2011
Slide 17
The application of ERGO-MTM
requires a deep understanding and a
structured delivery mode
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© 2011 PricewaterhouseCoopers Advisory SpA. All rights reserved. In this document, “PwC”
refers to PricewaterhouseCoopers Advisory SpA which is a member firm of
PricewaterhouseCoopers International Limited, each member firm of which is a separate legal
entity.
Gabriele Caragnano
Associate Partner
Mobile: +393482298333
[email protected]
Ivan Lavatelli
Director
Mobile: +393482298332
[email protected]
www.pwc.com/it
© 2011 PricewaterhouseCoopers. All rights reserved. In this document, “PwC” refers to
PricewaterhouseCoopers Advisory SpA, which is a member firm of PricewaterhouseCoopers
International Limited, each member firm of which is a separate legal entity.