Motion study examines the movements an operator makes to do a job, looking for movements that can be removed, shortened or made easier. In sewing, the machine time is often fixed by seam length and speed, but handling time (picking up, aligning, repositioning, disposing) can be reduced a great deal. That is where motion study pays off.
Principles of motion economy for sewing#
These principles come from classic motion study and are easy to apply at a sewing station:
- Use both hands at the same time: pick up two parts together, one in each hand.
- Keep movements short: place bundles and finished work close to the operator, within the normal reach area.
- Avoid searching and selecting: parts should be stacked in the same orientation, ready to pick up.
- Use gravity: slide finished work down a chute or into a bin instead of lifting it.
- Reduce repositioning: every time the operator stops, lifts the foot and turns the part, time is added.
- Use guides and attachments: folders, edge guides and templates replace hand control.
- Keep a comfortable posture: correct chair and table height, and the machine at the right distance.
How to study an operation#
- Record on video from a position that shows both hands and the machine.
- Break the operation into elements: pick up, align, sew, reposition, sew, cut thread, aside.
- Time each element by playing the video slowly.
- Ask of each element: can it be eliminated, combined, simplified or done by the machine?
- Try the new method with the operator and time it again.
Examples of improvements#
| Operation | Problem | Change | Effect |
|---|---|---|---|
| Label attach | Operator searches for labels in a box | Labels pre-counted and stacked in a holder at the left hand | Less searching time |
| Side seam | Parts on a table behind the operator | Bundle clamp on the left at machine height | Shorter reach, no turning |
| Hemming | Hand folding before sewing | Hemming folder on the machine | Fold and sew in one step |
| Pocket attach | Marking the position with chalk | Template or marking at cutting | Marking removed from sewing |
| Thread trimming | Scissors each piece | Automatic thread trimmer | Faster cycle, cleaner garments |
Workstation layout#
A good sewing workstation has:
- Incoming work on the left (for most operations) at table height.
- Outgoing work on the right or behind, where it can be dropped without looking.
- Tools (scissors, gauges) in fixed positions.
- Lighting focused on the needle area.
- Chair height set so that the forearms are roughly level with the table.
A tidy, standard layout is also a 5S practice.
Measuring the result#
After a method change, run a short time study and compare the new standard with the old. Update the operation SMV and train other operators on the new method.
Common mistakes#
- Asking operators to "work faster" instead of improving the method.
- Changing the method without training, so operators fall back to old habits.
- Ignoring comfort: a method that saves seconds but causes strain will not last.
Related guides#
- Work study: where motion study fits within method study and work measurement.
- Bottleneck analysis: choosing which station to study first.
- Kaizen: turning method changes into continuous improvement.
- Operator skill matrix: training operators on the improved method.
Frequently asked questions#
Is motion study only for new styles? No. Running styles often have the most to gain, because small savings repeat on every garment.