Motherson Time Study

Challenge

Motherson, the largest tier-one supplier to Mercedes-Benz U.S. International (MBUSI), operates three facilities in Cottondale and Vance, AL. These plants manufacture injection-molded parts such as bumpers, door panels, rocker panels, spoilers, and more, all produced Just-In-Time and In-Sequence to align with MBUSI’s production schedule. This required Motherson to maintain an uninterrupted flow of parts while also seeking new efficiency and cost-saving opportunities, without disrupting production.

Solution

Motherson partnered with APC to conduct both standard time studies and a more detailed Methods-Time Measurement (MTM) study using the Maynard Operational Sequence Technique (M.O.S.T.). APC analyzed over 500 workstations, capturing every detail of movement, from tool grasps to part snaps, and developed a custom tool to automatically generate:

• Yamazumi Charts

• Value vs. Non-Value Add Charts

• Standard Work Combination Charts

To ensure long-term improvement, APC also trained more than a dozen Motherson employees on M.O.S.T. and the custom analysis tool, creating a living system for continuous improvement.