Motion Study — Analyzing Worker Movements in Manufacturing
Motion study is the systematic analysis of worker movements during a task to identify and eliminate unnecessary motions. Originating from Frank and Lillian Gilbreth's work in the early 1900s, modern motion study uses video technology to capture and analyze movements at frame-level accuracy. The goal is to design work methods that minimize physical effort while maximizing productivity and ergonomic safety.
Anatomy of the Chart
- Movement element
- One discrete motion — reach, grasp, position, release.
- Frame-level boundary
- Where one movement ends and the next begins; the precision the method depends on.
- Classification
- Value-adding, incidental work or waste, applied per movement.
- Reach distance
- How far the hand travels — the variable most often reduced by layout.
- Before / after recording
- The pair of measurements that proves a motion was removed, not relocated.
How to Create
- 1
Record the operator performing the task
Frame-level accuracy is what separates motion study from watching; the movements being removed are often two or three seconds long.
- 2
Tag each movement element frame by frame
Break the cycle into individual movements rather than one duration per task.
- 3
Classify every movement
Value-adding, incidental work, or waste. Reaching, searching and repositioning are motions that cost time and add nothing.
- 4
Chart productive against non-productive motion
A Yamazumi chart makes the proportion visible, which is what turns an observation into a case.
- 5
Redesign the workstation or the method
Move what is reached for closer, remove what is searched for, and re-record to confirm the motion is gone.
Example
An electronics manufacturer analyzed a manual PCB assembly operation. Motion study via Yamazo Studio revealed that the operator made 14 reach-and-return motions per cycle to a parts bin 60cm away. Relocating the bin to within 20cm eliminated 8 of these motions, reducing cycle time by 11 seconds (18% improvement).
Related Terms
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Frequently Asked Questions
Take the template with you
We will email you the element time study template — station, element, category and five cycle columns, with worked example rows already filled in. The same email carries the Yamazo Studio demo links, in case you want to measure the same thing from video instead.