Motherson
APC Consulting Success Story
Time Studies Supporting Continuous Improvement
APC performed standard and methods-time measurement studies for three Motherson plants located in Cottondale and Vance, Alabama. Motherson is a major tier-one supplier to Mercedes-Benz U.S. International and produces injection-molded components including bumpers, door panels, rocker panels, running boards, spoilers, and other automotive parts.
These components are produced in a Just-in-Time and In-Sequence environment. Many parts are manufactured, delivered, and installed on a finished Mercedes-Benz vehicle on the same day they are ordered. The sequence of parts shipped by Motherson must match the exact order of vehicles being assembled, including the model, selected options, and exterior colors.
The Challenge
Evaluating Improvements Without Interrupting Production
Mercedes-Benz requires suppliers to maintain a constant flow of parts to the final assembly line without interruption. This creates a challenge for suppliers that want to test process improvements, rebalance work, or introduce cost-saving changes while protecting production continuity.
Motherson partnered with APC to create a more accurate picture of how work was being performed throughout its facilities. APC began by conducting standard time studies for each assembly line.
Once the standard studies were complete, Motherson requested a more detailed methods-time measurement analysis using the Maynard Operational Sequence Technique, commonly known as M.O.S.T.
APC analyzed more than 500 workstations. Each required movement was broken down into small details, including steps taken, tools or parts grasped, components positioned, and pieces snapped together.
Project Deliverables
Visual Tools for Process Analysis
APC applied M.O.S.T. using a custom-developed tool that automatically produced Yamazumi charts, value-added and non-value-added reports, and standardized work combination charts.
Long-Term Use
Supporting Continuous Improvement at Motherson
APC designed the time studies to function as living documents. More than a dozen Motherson employees were trained in both M.O.S.T. and the custom APC tool so the company could continue updating the studies and evaluating future changes.
Motherson has already used the findings to re-evaluate the installation of a new assembly line before construction was complete, with plans to increase its investment by approximately $350,000.
The project also gave fifteen University of Alabama student interns from varied academic backgrounds hands-on experience with time studies, M.O.S.T., manufacturing systems, process improvement, and automotive production in Alabama.
Measurable Results
Project Impact
500+
Workstations Analyzed
15
UA Student Interns
$6.8M
Expected Annual Savings
$7.37M
Estimated Total Impact
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