What Is Maynard Operation Sequence Technique? (Explained Super Simple!)

The Maynard Operation Sequence Technique, or MOST, is a powerful work measurement system used by companies to make jobs easier, faster, and more efficient. It’s like giving a job a simple map and stopwatch so workers can do tasks quickly without wasting time. Think of it as a smart way to figure out how long a task should take when done the best way possible.

What Is the Maynard Operation Sequence Technique (MOST)?

The Maynard Operation Sequence Technique, often simply called MOST, is a predetermined motion time system used to analyze work and improve job performance. It breaks down any manual task into small steps and assigns a standard time value to each. These small steps are called sequence models, and MOST provides a super structured way to measure them without needing to time each move in real life.

Instead of measuring every second with a stopwatch, MOST gives a reliable time estimate for each task by using standard motion patterns like lifting, walking, placing, or turning. That means even before someone starts a job, we already know how long it should take based on these patterns. It’s like having a recipe for every action a person does at work, and the recipe tells you how long it will take.

MOST was designed to be faster and simpler than older work measurement methods like MTM (Methods-Time Measurement) or traditional time studies. This method is accurate enough for planning but simple enough that it doesn’t take hours to apply.

Why Do Companies Use MOST?

Companies use MOST because it saves time, cuts costs, and improves productivity without making workers feel rushed. Businesses want their processes to be as lean and efficient as possible, and MOST helps them figure out the best way to do a task with the least amount of effort and time.

Imagine a factory where someone has to put parts together. MOST helps managers figure out if that worker is doing it in the best possible way. If not, they can adjust the process so it’s quicker and smoother. This means less wasted motion, fewer errors, and less physical strain on workers. That’s why companies in manufacturing, logistics, automotive, and even healthcare use MOST to get better results.

Another reason companies love MOST is because it’s less complicated and more cost-effective than older systems. It gives enough precision for real-world use while still being quick to apply. You don’t need to measure every move – you just need to plug steps into the MOST model.

How Does MOST Work in Real Life?

MOST works by looking at how people move and what they do during a job. It breaks actions into motion sequences like reaching, grasping, moving, and placing items. Then, it assigns a time value to each action based on standard data. The total time for a job is the sum of all these tiny movements.

Let’s say someone is picking up a box and putting it on a shelf. MOST doesn’t just say “lift the box.” It breaks that into: reach for box, grasp box, move box, position it, and release it. Each of these actions has a number value based on time units (called TMUs – Time Measurement Units), and MOST calculates the total time for all these steps together.

Watching the Work Step by Step

The first part of using MOST is watching how a task is done, step by step. The analyst watches a worker perform a task and breaks the task into smaller actions. These actions are not random – they follow specific models like the General Move, Controlled Move, and Tool Use. This helps ensure consistency and accuracy.

This step is all about observation. The person using MOST pays attention to everything – how a worker walks, bends, picks up tools, or turns around. Each of these steps adds to the total time needed, and that’s what MOST helps define and measure.

Timing Each Step Smartly

Instead of using a stopwatch, MOST uses predefined time values based on research. So when someone reaches for a tool, there’s already a standard time for that move. This saves a ton of time for managers and engineers and still gives very accurate results.

This smart timing system makes MOST incredibly useful in industries where speed and precision matter. It avoids the guesswork of stopwatch timing, and it’s much quicker than older methods. As a result, companies can make smart decisions without wasting time or money.

Improving the Job Easily

Once you know how long a job should take, it’s easy to spot problems. Maybe a worker takes too many steps or turns too much. Maybe the tools are placed too far away. With MOST, you can make small changes – like moving the tool closer – and that can save time and make the job easier.

MOST doesn’t just show you problems – it gives you real solutions. It helps companies design workstations better, organize tasks more efficiently, and reduce stress on workers. That’s why it’s not just a tool for measuring work; it’s a tool for improving it.

MOST vs Other Work Methods

There are many work measurement methods out there, like MTM, stopwatch time studies, and work sampling. But MOST stands out because it strikes a balance between speed and accuracy. It’s not as detailed as MTM (which looks at each micro-movement), but it’s much faster to use.

Time studies, for example, involve watching workers with a stopwatch, which can be time-consuming and sometimes inaccurate if workers behave differently when watched. MOST avoids this by applying standard models to tasks.

Compared to older systems, MOST is less costly to apply, requires less training, and gives reliable results faster. That’s why many companies today prefer it over older, more complicated methods.

Where Is MOST Used Today?

MOST is used in manufacturing, automotive, warehousing, aerospace, healthcare, and even in military logistics. Any industry where time, motion, and effort matter can benefit from this technique. For example:

• Automotive companies use MOST to improve assembly line tasks.
• Logistics companies use it to streamline package handling and sorting.
• Hospitals may use it to study how nurses move between patients and equipment.

In the US, where manufacturing and service industries rely heavily on time and motion efficiency, MOST is a popular choice for operations managers, industrial engineers, and lean practitioners.

Who Created the MOST System?

MOST was developed by a group of engineers who wanted to create a faster and easier alternative to MTM. The system was introduced by H. B. Maynard and Company, Inc., a firm that specialized in improving industrial efficiency. That’s why it’s called the Maynard Operation Sequence Technique.

A Little About H.B. Maynard

Harrington Emerson Maynard Jr., often called H.B. Maynard, was an American engineer known for his work in industrial engineering. His company, H.B. Maynard and Co., focused on work measurement and motion studies. Maynard believed that work should be easier and more organized – and that’s exactly what MOST helps do.

When Was MOST First Used?

MOST was first introduced in the late 1960s and early 1970s, building on the ideas of motion economy and time studies. It was designed during a time when industries were shifting toward more lean manufacturing and just-in-time processes.

Companies needed faster ways to measure and improve work, and MOST became the go-to method for many industries in the United States and worldwide. Since then, it has been constantly refined and updated to meet modern workplace needs.

Easy Examples of Using MOST

Let’s say a warehouse worker picks up a box, scans it, and places it on a shelf. With MOST, we’d break this into:

• Reach for scanner (Standard TMU value)
• Grasp scanner
• Position it
• Press button
• Put scanner down
• Lift box
• Walk to shelf
• Place box

Each step has a time value. When added together, you get the total time for the task. If the time is too long, you look at ways to improve – maybe place the scanner closer or reduce walking distance.

Benefits of MOST (Why It’s Awesome)

The biggest benefit of MOST is efficiency. It helps companies save time, cut costs, and improve worker productivity – all without making people work harder. It also helps reduce physical stress on employees by identifying and removing unnecessary movements.

MOST is also easier and quicker to learn compared to traditional methods. It doesn’t need complex software or hours of video recording. Once trained, engineers can analyze tasks in minutes. It’s perfect for today’s fast-moving industries that need answers quickly.

Other benefits include:

• Better workstation design
• Improved training programs
• Fewer injuries from repetitive tasks
• Greater process standardization
• Higher output with less input

The Bottom Line

The Maynard Operation Sequence Technique is one of the smartest and most effective ways to study and improve work. Whether it’s lifting boxes in a warehouse, assembling a car part, or delivering medicine in a hospital, MOST helps figure out the best way to do the job with less waste and more speed.

It’s simple, fast, and powerful – and that’s why businesses across the US and around the world trust it. With MOST, companies can get better results without overworking people, which is a win for both business and workers.