MTM2 SMV Calculation: The Ultimate Tool for Industrial Engineers in Apparel Manufacturing

Introduction

In the fast-paced world of apparel manufacturing, efficiency is everything. Industrial engineers constantly seek ways to optimize production processes, reduce waste, and improve workflow. One of the most powerful tools at their disposal is the MTM2 SMV calculation method. This advanced technique helps measure Standard Minute Value (SMV)—a critical metric for determining labor productivity.

With the rise of digital tools, MTM2 SMV calculation software has revolutionized how factories analyze and optimize operations. In this guide, we’ll explore how this tool works, its benefits for industrial engineers, and step-by-step instructions on using it effectively.

What is MTM2 SMV Calculation?

MTM2 (Methods-Time Measurement 2) is a predetermined motion time system (PMTS) used to analyze manual work processes. It breaks down operations into basic movements, assigning Time Measurement Units (TMU) to each.

The SMV (Standard Minute Value) represents the time a skilled worker needs to complete a task under standard conditions. By using an MTM2 SMV calculation tool, industrial engineers can:
✔ Accurately measure production time
✔ Identify bottlenecks in workflows
✔ Optimize labor allocation
✔ Reduce unnecessary motions
✔ Improve overall efficiency

How to Use the MTM2 SMV Calculation Tool

Step 1: Enter Operation Details

1. Operation Name – Define the task (e.g., "Sleeve Attachment").
2. Machine Name – Specify the machine used (e.g., "Overlock Machine").
3. Allowance % – Add relaxation, fatigue, and delay allowances (typically 10-20%).
4. Sewing Time (Seconds) – Input observed sewing time.

Step 2: Input MTM2 Codes

The tool categorizes MTM2 codes into:

• GET Codes (Retrieving materials)
• PUT Codes (Placing materials)
• Other Codes (Additional motions like bending or eye focus)

For each code:
✔ Select the appropriate movement (e.g., *GA15 for "Get Approximate 5-15 cm"*)
✔ Enter the quantity of repetitions

Step 3: Calculate SMV

The tool automatically computes:

• Elements Total TMU (Sum of all motion times)
• Sewing Time TMU (Converted from seconds)
• Cumulative TMU (Total time in TMU)
• Final SMV (Including allowances)

Step 4: Export & Analyze

Download the report in Excel for further analysis, line balancing, and process improvement.

Advantages of MTM2 SMV Calculation for Industrial Engineers

In the highly competitive apparel manufacturing industry, efficiency and precision are critical for maintaining profitability. Industrial engineers play a pivotal role in optimizing production processes, and the MTM2 SMV calculation method has emerged as a game-changing tool. This section delves deeper into the five key advantages of using MTM2-based SMV analysis, explaining how it revolutionizes production planning, cost management, and workforce productivity.

1. Accurate Time Measurement: Eliminating Guesswork in Production

Why Traditional Methods Fall Short

Historically, factories relied on stopwatch time studies, where analysts manually recorded task durations. While useful, this method had limitations:

• Human error – Different observers may record varying times.
• Subjectivity – Workers may speed up or slow down during observation.
• Inconsistent benchmarks – Results vary between factories.

How MTM2 SMV Calculation Enhances Precision

The MTM2 (Methods-Time Measurement 2) system eliminates these issues by:
✔ Predefined motion codes – Every movement (e.g., reaching, grasping, placing) has a fixed TMU (Time Measurement Unit).
✔ Consistent standards – Unlike manual studies, MTM2 ensures uniform measurements across different analysts.
✔ Data-driven decisions – Engineers can trust the accuracy of SMV calculations for fair workload distribution.

Real-World Impact

A Bangladeshi garment factory reported a 12% reduction in time-study disputes after switching from stopwatch studies to MTM2. Workers and managers agreed on standardized times, improving transparency and trust.

2. Improved Production Planning: Smarter Workflow Management

The Challenge of Unoptimized Production Lines

Without accurate SMV data, factories face:

• Unrealistic targets – Leading to worker burnout or underutilization.
• Bottlenecks – Some workstations lag, while others remain idle.
• Overtime costs – Poor planning leads to rushed orders and extra labor expenses.

How MTM2 SMV Optimizes Planning

By providing precise time measurements, MTM2 helps factories:

✔ Set Realistic Production Targets

• Factories can calculate exact capacity per line based on SMV.
• Example: If a sewing operation has an SMV of 0.75 minutes, a line with 30 workers can produce 320 pieces/hour (assuming 100% efficiency).

✔ Optimize Manpower Allocation

• Engineers can balance workloads by assigning operators based on skill level and task complexity.
• Prevents overburdening workers in high-SMV operations.

✔ Reduce Idle Time

• MTM2 identifies non-value-added motions (e.g., excess walking, searching for materials).
• Factories can rearrange workstations to minimize wasted movements.

Case Study: Increased Output by 18%

A Sri Lankan apparel manufacturer implemented MTM2-based line balancing and saw an 18% increase in daily output within three months.

3. Cost Reduction: Cutting Waste Without Compromising Quality

Hidden Costs in Apparel Manufacturing

Many factories lose money due to:

• Excess labor costs – Overstaffing or inefficient task assignments.
• Material waste – Poor handling leads to fabric damage.
• Energy inefficiency – Machines running longer than necessary.

How MTM2 SMV Lowers Expenses

✔ Minimize Unnecessary Movements

• MTM2 pinpoints redundant motions (e.g., double-handling materials).
• Factories can redesign workflows to shorten motion paths.

✔ Lower Labor Costs

• Accurate SMV prevents overstaffing.
• Example: If an operation requires 2.5 SMV, a factory can calculate the exact number of workers needed per shift.

✔ Reduce Material Waste

• Smoother workflows mean less fabric damage from excessive handling.
• Fewer errors mean fewer rejected pieces, saving material costs.

Example: 15% Labor Cost Savings

A Vietnamese textile factory reduced labor costs by 15% after optimizing workflows using MTM2 data.

4. Enhanced Worker Productivity: Building a More Efficient Workforce

Common Productivity Killers

• Inconsistent work methods – Different workers perform tasks differently.
• Fatigue – Repetitive or awkward motions lead to exhaustion.
• Poor training – New hires take longer to reach full efficiency.

How MTM2 SMV Improves Workforce Performance

✔ Standardizing Work Methods

• MTM2 defines the most efficient way to perform each task.
• All workers follow the same optimized motions, reducing variability.

✔ Training Operators Efficiently

• New hires learn best practices from day one.
• Training time decreases as workers follow predefined motion sequences.

✔ Reducing Fatigue Through Ergonomics

• MTM2 identifies high-strain motions (e.g., excessive bending).
• Factories can introduce ergonomic tools (e.g., adjustable chairs, material feeders).

Case Study: 25% Faster Training Time

An Indian garment factory reported that workers trained using MTM2-based methods reached full productivity 25% faster than traditional training.

5. Digital Integration & Reporting: The Future of Smart Manufacturing

The Limitations of Manual Record-Keeping

• Human errors in data entry.
• Slow reporting delays decision-making.
• No real-time insights for quick adjustments.

How Modern MTM2 Tools Enhance Efficiency

✔ Automated Excel Exports

• Engineers can generate instant reports for line balancing.
• Data can be shared with management and clients seamlessly.

✔ Real-Time Data Tracking

• Digital MTM2 tools update SMV calculations live as inputs change.
• Factories can adjust workflows on the fly to meet targets.

✔ ERP System Integration

• SMV data syncs with Enterprise Resource Planning (ERP) software.
• Enables automated production scheduling and resource allocation.

Example: 30% Faster Decision-Making

A Turkish denim manufacturer integrated MTM2 with its ERP system, reducing planning time by 30%.

Why Industrial Engineers Need This Tool

The apparel industry is highly competitive, with slim profit margins. MTM2-based SMV calculation provides:
✅ Data-driven decision-making – No more guesswork in production planning.
✅ Faster line balancing – Quickly adjust workflows for maximum efficiency.
✅ Global compliance – Meet international labor standard requirements.

According to a study by the International Journal of Industrial Engineering, factories using MTM2 methods saw a 15-20% increase in productivity.

MTM2 Codes in Apparel Manufacturing

The MTM2 (Methods-Time Measurement 2) system is a predetermined motion time system (PMTS) widely used in the apparel industry to analyze and optimize production processes. It breaks down manual operations into fundamental motions, each assigned a Time Measurement Unit (TMU).

Understanding MTM2 codes is crucial for industrial engineers, production managers, and lean manufacturing specialists who aim to:
✔ Standardize work methods
✔ Improve efficiency
✔ Reduce unnecessary motions
✔ Calculate accurate SMV (Standard Minute Value)

In this guide, we’ll explore all MTM2 codes with real-world examples from garment manufacturing, helping you apply them effectively in your factory.

Understanding MTM2 Motion Categories

MTM2 codes are divided into three main categories:

1. GET Codes – Retrieving materials or parts

2. PUT Codes – Placing or positioning materials

3. Other Motion Codes – Additional actions like bending, eye focus, or cranking

Each code has a specific TMU value based on:
✔ Distance moved (0-5 cm, 5-15 cm, etc.)
✔ Precision required (Approximate, Accurate, Precise)
✔ Body parts involved (Fingers, Wrist, Elbow, Shoulder, Trunk)

1. GET Codes – Retrieving Materials in Garment Production

GA (Get Approximate) Codes

Used when rough positioning is sufficient.

Example: Picking Up Fabric Pieces

• GA5 (3 TMU) – Picking a small button from a nearby tray (0-5 cm).

• GA15 (6 TMU) – Reaching for a folded collar piece 10 cm away.

• GA30 (9 TMU) – Grabbing a sleeve panel from a rack 20 cm away.

GB (Get Accurate) Codes

Used when moderate precision is needed.

Example: Aligning Fabric for Sewing

• GB5 (7 TMU) – Precisely gripping a needle from a holder.

• GB30 (14 TMU) – Positioning a pocket piece accurately before stitching.

GC (Get Precisely) Codes

Used for high-precision tasks.

Example: Handling Delicate Materials

• GC5 (14 TMU) – Carefully picking up a sequin for embellishment.

• GC45 (27 TMU) – Aligning a zipper perfectly before attaching.

2. PUT Codes – Positioning Materials in Garment Assembly

PA (Put Approximate) Codes

Used for general placement without precision.

Example: Dropping Cut Fabric

• PA5 (3 TMU) – Dropping a trimmed thread into a waste bin.

• PA80 (20 TMU) – Placing a finished garment on a distant conveyor.

PB (Put Accurate) Codes

Used when controlled placement is required.

Example: Attaching Garment Components

• PB15 (15 TMU) – Positioning a sleeve into an armhole.

• PB45 (25 TMU) – Aligning a waistband before stitching.

PC (Put Precisely) Codes

Used for exact positioning.

Example: Fine Detailing

• PC5 (21 TMU) – Placing a small bead on embroidery.

• PC30 (30 TMU) – Aligning a delicate lace trim.

3. Other Essential MTM2 Codes in Apparel Manufacturing

A (Apply Pressure – 14 TMU)

• Example: Pressing an iron on a seam.

R (Re-grasp – 6 TMU)

• Example: Adjusting grip on slippery fabric.

E (Eye Action – 7 TMU)

• Example: Inspecting stitch quality.

C (Crank – 15 TMU)

• Example: Rotating a sleeve for topstitching.

S (Step – 18 TMU)

• Example: Moving between sewing machines.

B (Bend & Arise – 61 TMU)

• Example: Picking up fabric from a lower bin.

How to Calculate SMV Using MTM2 Codes

Step-by-Step Process

1. Break down the operation into motions (e.g., pick fabric, align, stitch).

2. Assign MTM2 codes to each motion.

3. Sum the TMUs for all motions.

4. Convert TMU to minutes (1 TMU = 0.0006 min).

5. Add allowances (fatigue, delay) to get SMV.

Example: T-Shirt Side Seam Stitching

SMV = (20 TMU × 0.0006) + Allowances

Why MTM2 Codes Matter in the Apparel Industry

1. Standardized Work Methods – Ensures consistency across workers.

2. Fair Labor Standards – Prevents unrealistic time expectations.

3. Reduced Fatigue – Minimizes unnecessary motions.

4. Better Costing – Accurate SMV helps price garments competitively.

According to a study by the International Journal of Clothing Science, factories using MTM2 reduced motion waste by 22%.

Mastering MTM2 codes is essential for apparel industry professionals seeking to optimize production. By applying these codes correctly, factories can:
✅ Improve efficiency
✅ Reduce costs
✅ Enhance product quality

Conclusion

The MTM2 SMV calculation tool is a game-changer for industrial engineers in apparel manufacturing. By automating time studies, reducing human error, and providing actionable insights it helps factories stay competitive in a demanding market.

The MTM2 SMV calculation tool is not just a time-study method—it’s a strategic asset for industrial engineers. From accurate time measurement to digital integration, this system helps factories:
✅ Boost efficiency – Eliminate wasted motions and optimize workflows.
✅ Cut costs – Reduce labor, material, and energy waste.
✅ Enhance productivity – Standardize work methods and improve training.

For factories looking to stay ahead in the competitive apparel industry, adopting MTM2 SMV calculation is no longer optional—it’s essential.

Ready to optimize your production line? Try our free MTM2 SMV Calculator and experience the difference!