Motion Analysis Using Therbligs & Micro-Motion Study
Lesson Contents Overview
Learning Objectives
Comprehensive Technical GuidanceTextbook & Training SOP
Motion Analysis Using Therbligs & Micro-Motion Study
═══════════════════════════════════════════════════════════════════════════════ MODULE 03: MOTION & METHOD STUDY LESSON 03.04: MOTION ANALYSIS USING THERBLIGS & MICRO-MOTION STUDY ═══════════════════════════════════════════════════════════════════════════════ [Course: SMV & Industrial Engineering Masterclass] [🎉 MODULE 03 COMPLETE!]
1. Executive Overview: The Molecular Science of Human Work
In apparel industrial engineering, if Method Study is the macro-anatomy of work, Therbligs and Micro-Motion Study represent its molecular physics.
Invented by industrial engineering pioneers Frank and Lillian Gilbreth, Therbligs (Gilbreth spelled backward with transposition) are the 17 fundamental, elemental building blocks of human motion that compose every manual operation performed in an apparel factory.
┌─────────────────────────────────────────────────────────────────────────────┐
│ THE THERBLIG CLASSIFICATION ARCHITECTURE │
└─────────────────────────────────────────────────────────────────────────────┘
[17 THERBLIGS]
│
┌───────────────────┴───────────────────┐
▼ ▼
[EFFECTIVE THERBLIGS] [INEFFECTIVE THERBLIGS]
(Directly Advance Work) (Pure Non-Value-Added Waste)
• Grasp (G) • Search (Sh)
• Transport Loaded (TL) • Find (F)
• Assemble (A) • Select (St)
• Use (U) • Hold (H)
• Release Load (RL) • Pre-Position (PP)
• Transport Empty (TE) • Plan (Pn)
│ • Avoidable Delay (AD)
▼ │
[OPTIMIZE & SHORTEN] ▼
(Reduce reach distance) [COMPLETELY ELIMINATE]
(Use jigs, guides, folders)2. The 17 Fundamental Therbligs Explained with Garment Examples
┌─────────────────────────────────────────────────────────────────────────────┐ │ THE 17 THERBLIGS IN APPAREL SEWING │ ├────┬────────────────────────┬───────┬───────────────────────────────────────┤ │ NO │ THERBLIG NAME │ SYMBOL│ APPAREL SEWING EXAMPLE │ ├────┼────────────────────────┼───────┼───────────────────────────────────────┤ │ 1 │ Search │ Sh │ Looking across table for thread snips │ │ 2 │ Find │ F │ Eyes locating the fabric notch point │ │ 3 │ Select │ St │ Picking 1 ply from sticky 50-ply stack│ │ 4 │ Grasp │ G │ Closing fingers firmly on pocket ply │ │ 5 │ Transport Empty │ TE │ Empty hand reaching out to bundle tray│ │ 6 │ Transport Loaded │ TL │ Hand carrying fabric ply to needle │ │ 7 │ Hold │ H │ Left hand clamping fabric during sew │ │ 8 │ Release Load │ RL │ Letting go of sewn piece at seam end │ │ 9 │ Position │ P │ Aligning seam edges under needle foot │ │ 10 │ Pre-Position │ PP │ Flipping collar right-side up in hand │ │ 11 │ Inspect │ I │ Pausing to check stitch SPI/tension │ │ 12 │ Assemble │ A │ Bringing pocket and front panel match │ │ 13 │ Disassemble │ DA │ Snapping thread chain at seam exit │ │ 14 │ Use │ U │ Depressing pedal & machine stitching │ │ 15 │ Unavoidable Delay │ UD │ Waiting for auto trimmer blade action │ │ 16 │ Avoidable Delay │ AD │ Operator looking around or chatting │ │ 17 │ Plan │ Pn │ Hesitating on how to fold corner curve│ └────┴────────────────────────┴───────┴───────────────────────────────────────┘
3. The 3 Primary Micro-Motion Wastes in Garment Assembly
When auditing sewing lines with high-speed video, industrial engineers repeatedly uncover three critical Therblig bottlenecks:
1. The "Search & Select" (Sh / St) Bottleneck:
- The Symptom: Operator spends 2 to 4 seconds peeling apart cut plies that have fused edges or rummaging through disordered bundle boxes.
- The Root Cause: Dull cutting room knives (causing fused edges) or lack of bundle ply separator tabs.
- The Cure: Install air-blast separator nozzles and enforce pristine cutting knife sharpening routines.
2. The "Hold" (H) Waste:
- The Symptom: Operator's left hand remains static, acting as a human clamp to keep fabric straight while the right hand guides.
- The Root Cause: Lack of edge guides or tensioning folders.
- The Cure: Install magnetic edge binders or vacuum plates. Freeing the left hand immediately enables two-handed simultaneous assembly.
3. The "Pre-Position" (PP) Waste:
- The Symptom: Operator picks a piece upside down or backward and must spend 0.05 minutes twirling the fabric in mid-air before placing it under the needle.
- The Root Cause: Bundles stacked randomly in cutting/fusing.
- The Cure: Enforce standard bundle stacking orientations so every panel is picked in the exact sewing orientation.
4. High-Definition Video Micro-Motion Study & Simo Charts
A Simo Chart (Simultaneous Motion Chart) plots the micro-motions of the Left Hand alongside the Right Hand across a vertical time axis calibrated in winks ($1 wink = 1/2000 minute = 0.03 seconds$):
┌─────────────────────────────────────────────────────────────────────────────┐ │ SIMULTANEOUS MOTION (SIMO) CHART BLUEPRINT │ ├───────┬──────────────────────────────┬───────┬──────────────────────────────┤ │ TIME │ LEFT HAND MOTION │ SYM │ RIGHT HAND MOTION │ ├───────┼──────────────────────────────┼───────┼──────────────────────────────┤ │ 0.00s │ Reach to Front Body (TE) │ ◄───► │ Reach to Back Yoke (TE) │ │ 0.04s │ Grasp Front Body (G) │ ◄───► │ Grasp Back Yoke (G) │ │ 0.08s │ Move to Needle Plate (TL) │ ◄───► │ Move to Needle Plate (TL) │ │ 0.12s │ Position on Needle Line (P) │ ◄───► │ Position on Needle Line (P) │ │ 0.18s │ Guide Left Seam Edge (U) │ ◄───► │ Guide Right Seam Edge (U) │ │ 0.35s │ Release Sewn Garment (RL) │ ◄───► │ Reach for Next Bundle (TE) │ └───────┴──────────────────────────────┴───────┴──────────────────────────────┘
5. From Therbligs to Predetermined Motion Time Systems (GSD / PMTS)
Therbligs provided the scientific foundation for modern Predetermined Motion Time Systems (PMTS) like General Sewing Data (GSD) and MTM-2.
Instead of timing with stopwatches, GSD groups fundamental Therblig combinations into pre-rated standard codes:
- $Get and Align (GA) = Transport Empty (TE) + Grasp (G) + Transport Loaded (TL) + Position (P)$
- $Sew Seam (SS) = Use (U)$
- $Dispose Piece (DP) = Transport Loaded (TL) + Release Load (RL)$
By understanding Therbligs at this granular level, an apparel industrial engineer can design perfect sewing workstation methods, synthesize accurate SMVs before physical production starts, and systematically eliminate line bottlenecks.
6. Summary of Module 03: Motion & Method Study
┌─────────────────────────────────────────────────────────────────────────────┐ │ MODULE 03 COMPLETE MASTERY SUMMARY │ ├─────────────────────────────────────────────────────────────────────────────┤ │ 1. Lesson 03.01: Mastered Motion Economy, reach envelopes, and Class 1-5. │ │ 2. Lesson 03.02: Executed 7-Step Method Study, Operation Breakdowns & ECRS. │ │ 3. Lesson 03.03: Applied Value-Added (VA), NNVA, NVA, and TIMWOODS wastes. │ │ 4. Lesson 03.04: Dissected micro-motions into the 17 Therbligs & Simo Charts│ └─────────────────────────────────────────────────────────────────────────────┘
1. The 17 Fundamental Therbligs in Garment Industrial Engineering
| Therblig Name | Symbol | Category | Sewing Shop-Floor Example | IE Improvement Opportunity |
|---|---|---|---|---|
| 1. Search (Sh) | 🔍 Sh | Ineffective (Waste) | Looking for lost thread snips or matching size tag | Fixed magnetic tool holder; pre-sorted tags |
| 2. Find (F) | 👁️ F | Ineffective (Waste) | Moment eyes locate the notch or thread end | High-contrast LED lighting and laser guide |
| 3. Select (St) | 🤏 St | Ineffective (Waste) | Choosing 1 cut ply from a sticky 50-ply bundle | Air-blower ply separator; pre-peeled plies |
| 4. Grasp (G) | ✊ G | Effective (Essential) | Fingers closing around fabric panel to pick up | Improve grip friction; use vacuum lifters |
| 5. Transport Empty (TE) | 🖐️ TE | Effective (Essential) | Hand reaching out to bundle box for next panel | Shorten reach distance to <35 cm |
| 6. Transport Loaded (TL) | 📦 TL | Effective (Essential) | Hand carrying fabric panel to the needle plate | Position bundle closer; slide instead of lift |
| 7. Hold (H) | 🛑 H | Ineffective (Waste) | Left hand holding fabric stationary while right works | Install mechanical edge clamp or guide folder |
| 8. Release Load (RL) | 🫳 RL | Effective (Essential) | Fingers letting go of fabric panel at end of seam | Use drop disposal / gravity slide chute |
| 9. Position (P) | 🎯 P | Effective (Essential) | Aligning fabric edge precisely under presser foot | Install mechanical stop-gauge or laser line |
| 10. Pre-Position (PP) | 🔄 PP | Ineffective (Waste) | Twisting or flipping panel into sewing orientation | Present cut plies pre-aligned from cutting room |
| 11. Inspect (I) | 🧐 I | Ineffective (Waste) | Stopping sewing to examine stitch tension or skipped stitch | Poka-Yoke sensors; automated thread break detectors |
| 12. Assemble (A) | 🧩 A | Effective (Essential) | Bringing two fabric plies together under the needle | Combine plies simultaneously using dual guides |
| 13. Disassemble (DA) | ✂️ DA | Effective (Essential) | Cutting thread chain with blade or snips | Equip machine with automatic undertrimmer (UBT) |
| 14. Use (U) | ⚙️ U | Effective (Essential) | Depressing foot pedal and machine stitching seam | Optimize motor RPM, feed dog, and needle size |
| 15. Unavoidable Delay (UD) | ⏳ UD | Ineffective (Allowance) | Waiting for machine automatic thread trimmer cycle | Ensure machine electronic sensors are calibrated |
| 16. Avoidable Delay (AD) | 🛑 AD | Ineffective (Waste) | Operator chatting, looking away, or unpicking error | Enforce standardized work pace and methods |
| 17. Plan (Pn) | 💭 Pn | Ineffective (Waste) | Operator hesitating to decide how to fold difficult seam | Comprehensive training and visual SOP at eye level |
| 18. Rest (R) | ☕ R | Ineffective (Allowance) | Pausing to overcome physical/mental fatigue | Provide ergonomic chair, armrests, and pedal rest |
2. Effective (Productive) vs. Ineffective (Wasteful) Therbligs Comparison
| Classification | Therbligs Included | Impact on Garment Production | IE Action Strategy |
|---|---|---|---|
| Effective Therbligs (Group 1) | Grasp (G), Transport Loaded (TL), Assemble (A), Use (U), Release Load (RL), Transport Empty (TE) | Directly advance the assembly and completion of the garment. | OPTIMIZE: Shorten motion distances, improve speeds, and combine simultaneous actions. |
| Ineffective Therbligs (Group 2 - Waste) | Search (Sh), Find (F), Select (St), Hold (H), Pre-Position (PP), Avoidable Delay (AD), Plan (Pn) | Consume operator time and energy with ZERO progress on the garment. | ELIMINATE: Redesign workstations, install mechanical folders, and standardize material presentation. |
| Allowances & Delays (Group 3) | Unavoidable Delay (UD), Rest for Overcoming Fatigue (R), Inspect (I) | Arise from human biological needs or machine cycle limits. | MINIMIZE: Ergonomic seating, automatic sensor monitoring, and balanced line flow. |
3. Video Micro-Motion Case Study: "Attach Collar Band to Shirt" (Before vs. After)
| Work Element Segment | Therbligs Before Study | Time Before (min) | Therbligs After Study | Time After (min) | Time Saved (%) |
|---|---|---|---|---|---|
| 1. Pick Shirt Body & Collar | TE + Sh + St + G + TL | 0.140 min | TE + G + TL (Two-handed) | 0.045 min | -67.9% |
| 2. Match & Orient Pieces | PP + P + Pn + H | 0.110 min | P (Pre-oriented jig) | 0.030 min | -72.7% |
| 3. Stitch Collar Band Seam | U + U + H + U | 0.220 min | U + U (Auto folder feed) | 0.140 min | -36.4% |
| 4. Trim Thread & Dispose | DA + TL + RL + AD | 0.090 min | DA (UBT) + RL (Drop chute) | 0.025 min | -72.2% |
| TOTAL OPERATION CYCLE | 17 Total Therbligs | 0.560 min | 6 Essential Therbligs | 0.240 min | -57.1% (Massive Win!) |
Practical Commercial Flow
An IE specialist conducted a micro-motion video study on the high-speed operation "Insert & Stitch Brand Woven Label under Back Neckband" (Measured baseline cycle time = 0.420 min):
Factory Real-Life Scenario
Scenario: An export lingerie factory in Colombo experienced inconsistent quality and high labor costs on the "Stitch Lace Border to Bra Cup" section. Operators took between 0.65 and 0.95 minutes per cup, with severe variances in stitch tension and alignment.
Solution: The IE team set up a Micro-Motion Study workstation with dual 120 fps cameras (one overhead angle and one needle-level profile). They constructed a Simo Chart mapping the micro-motions of both hands frame-by-frame. They discovered that operators performed 7 separate "Re-grasp" and "Re-position" Therbligs per cup because the lace ribbon curled as it fed.
Impact: The engineering team designed a heated Teflon guide attachment that automatically uncurled and tensioned the lace before it touched the cup. Re-grasp Therbligs were eliminated entirely. Cycle time dropped to a rock-solid 0.380 min across all operators, and lace puckering defects fell from 11.4% to 0.4%.
Commercial Officer Best Practice
Use slow-motion video playback (0.25x speed) during method reviews with line supervisors. Seeing micro-hesitations, double-grasps, and awkward finger repositions frame-by-frame turns abstract motion theory into undeniable visual proof.
Top Beginner Mistakes to Avoid
- Assuming Therbligs analysis is only for laboratory research; in reality, it is the most practical tool for resolving chronic shop-floor bottlenecks.
- Ignoring the "Hold" Therblig (using the operator’s hand as a human clamp instead of installing a mechanical guide).
- Allowing loose, unsorted material bundles that force operators to "Search" and "Select" plies during sewing.
- Conducting video analysis without informing the operator, causing anxiety and unnatural, staged working speeds.
- Failing to convert micro-motion study findings into visual SOP cards that line supervisors can enforce.
Important Commercial & Trade Terminology (7 Terms)
The 17 fundamental, elemental motions into which all human manual operations can be divided, established by Frank and Lillian Gilbreth.
💡 Note: The fundamental alphabet of human work measurement.The high-resolution recording and frame-by-frame analysis of operator body and hand movements using high-speed video photography and timing counters (wink counters).
💡 Note: Used for operations under 0.20 minutes.A graphic representation of an operation depicting the simultaneous Therbligs performed by the left and right hands against a calibrated vertical time scale.
💡 Note: Reveals one-handed idle time and asymmetry.Therbligs that directly progress the physical assembly of the product: Grasp, Transport Loaded, Assemble, Use, Release Load.
💡 Note: Must be optimized and streamlined.Therbligs that do not advance the assembly: Search, Find, Select, Hold, Pre-Position, Avoidable Delay, Plan.
💡 Note: Must be systematically eliminated.A work measurement methodology where standard times are established by synthesizing basic predetermined human motion time values (e.g. GSD, MTM, MODAPTS).
💡 Note: Built directly upon Therblig principles.The premier PMTS system engineered specifically for the sewn products and apparel manufacturing industry.
💡 Note: Uses 100% pre-rated standard data blocks.Interview Preparation Questions & Answers (5 Questions)
Master these high-frequency interview questions for Commercial Officer, Merchandising, and Export Executive roles.
A Therblig is one of the 17 fundamental elemental motions (such as Grasp, Move, Position, Assemble, Hold) into which any manual task can be decomposed. The concept was created by industrial engineering pioneers Frank and Lillian Gilbreth (with "Therblig" being Gilbreth spelled backward, with the "th" transposed).
Frequently Asked Questions (4 FAQs)
Clear, beginner-friendly answers to the most common questions about the Commercial Department.
Key Takeaways & Summary Points
Executive Lesson Summary
Micro-motion study and Therbligs analysis represent the highest level of industrial engineering craftsmanship in apparel manufacturing. By dissecting operations at the millisecond level, eliminating ineffective micro-motions, and balancing simultaneous two-handed work, industrial engineers turn complex sewing tasks into effortless, high-speed, and fatigue-free production routines.
Lesson Downloads & SOP Templates
Cycle Time Analyzer
Break down operation video time into micro-elements and Therblig groups.
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