Emmanuel Calvez is a visionary leader and a globally recognized expert in Methods-Time Measurement (MTM) and operational efficiency. With over 25 years of experience, he has collaborated with leading enterprises worldwide to optimize production systems, enhance competitiveness, and drive sustainable growth. His deep expertise and hands-on approach have established him as a trusted consultant in industrial engineering.
We are honored to welcome such a distinguished expert to LEAN AKADEMIJA 2025. Emmanuel is one of the foremost practitioners of MTM, a globally recognized methodology for analyzing and standardizing manual work processes. MTM enables organizations to accurately and consistently determine operation times, independent of individual performance variations. By leveraging this methodology, businesses can significantly improve efficiency, productivity, and ergonomic work design.
In this interview, Emmanuel shares his expertise, insights, and perspectives, while also offering a glimpse into his personal journey.
What key challenges related to the topic of your presentation have you successfully addressed, and how have they impacted business results?
Lean and MTM (Methods-Time Measurement) are globally recognized methodologies for maximizing production efficiency.
- Lean Manufacturingfocuses on a holistic analysis of the entire production process, eliminating waste and improving overall productivity.
- MTM, on the other hand, provides a detailed, localized analysis of individual tasks, ensuring each step is optimized for time and efficiency.
- Combining both methodologiescreates a powerful synergy, delivering high levels of efficiency by addressing both macro and micro aspects of production.
At its core, this approach brings us back to the fundamental principles of Industrial Engineering: analyzing and optimizing production methods. The key lies in identifying the optimal time—not just the shortest time, but the most practical and effective method. This means considering critical factors such as ergonomics, quality, investment, and safety alongside execution time.
Impact on Business Results:
By implementing these methodologies, we’ve achieved:
- 30% increase in productivity.
- Reduction in production waste leading to cost savings.
- Improved worker safety and ergonomics, resulting in fewer workplace injuries and higher employee satisfaction.
- Enhanced product quality, reducing defects and rework.
This approach has not only streamlined operations but also delivered measurable improvements in both efficiency and overall business performance.
How did you gain support from leadership and employees for implementing organizational methodologies, and what obstacles did you have to overcome?
Implementing MTM and Lean requires strong collaboration and commitment from leadership and employees. Here’s how we achieved it:
- Common Language:
MTM provides a standardized framework for describing and optimizing processes, creating alignment and trust across the organization. - Empowering Teams:
Employees analyzed their own workflows using MTM, fostering ownership and data-driven insights that matched their shop floor experience. - Inclusive Collaboration:
We brought together workers, managers, and leadership to discuss challenges and solutions, ensuring everyone worked toward shared goals. - Leveraging Lean Culture:
Existing Lean practices provided a foundation, making it easier to integrate MTM and drive efficiency and waste reduction.
Overcoming Obstacles:
- Resistance to Change:Addressed through quick wins and demonstrating MTM’s benefits.
- Communication Gaps:Bridged by transparent communication and clear goal setting.
- Sustaining Momentum:Maintained through continuous training, recognition, and feedback.
By combining structured methodologies, collaboration, and Lean principles, we built a culture of continuous improvement and delivered measurable results.
What innovative approaches or tools do you use to improve process efficiency, and what results have you achieved with them?
To enhance process efficiency, we utilize cutting-edge tools and methodologies, such as MTM (Methods-Time Measurement), advanced planning systems, and simulation techniques. Here’s how we implement these strategies and the outcomes we’ve delivered:
- MTM as a Diagnostic Tool:
MTM provides a data-driven, analytical approach to identify inefficiencies in processes. Think of it like a health check: MTM tells you your “current weight” (existing process performance) and shows you the “ideal weight” (optimal performance) if you make the right changes. This clarity helps teams focus on what not to do and prioritize improvements that deliver the most impact. - Integration with CAD Systems:
At the planning and design stages, we integrate MTM with CAD systems to develop both the product and the production process simultaneously. This ensures that efficiency is built into the design from the start, reducing the need for costly revisions later. First Time Right! - Standard Time use for Line Balancing and Simograms:
During production, we use Standard Time use in line balancing and Simograms to visualize and optimize human-machine interactions. These tools help us:- Balance workloads across stations to eliminate bottlenecks.
- Reduce idle time by synchronizing human and machine activities.
- Improve ergonomics and safety by identifying and addressing inefficiencies in workflows.
- Improvement Scenarios and Footprint Calculations:
We use MTM to calculate improvement scenarios, including footprint optimization and resource allocation. This allows us to simulate different configurations and select the most efficient one before implementation. Additionally, we incorporate principles of Industry 5.0, focusing on human-centric automation and collaboration between humans and machines to enhance productivity and innovation.
Results Achieved:
- 30% reduction in production cycle time.
- From 80 to 20% improvement in resource utilization, leading to cost savings.
- 15% increase in throughput without compromising quality or safety.
- Enhanced flexibility to adapt to changing production demands.
By combining analytical tools like MTM, advanced planning systems, and simulation techniques, we’ve created a culture of continuous improvement that delivers measurable results and positions us for future growth.
How does your improvement philosophy influence long-term strategy, especially in the context of digitalization and Industry 4.0?
Our improvement philosophy is centered on building a strong foundation for long-term efficiency and innovation, particularly in the context of digitalization and Industry 4.0/5.0. Here’s how we approach it:
- Training and Empowerment:
We focus on training multicultural teams in MTM (Methods-Time Measurement) techniques, ensuring they understand and apply the methodology correctly. This not only guarantees the quality and accuracy of the Time Data Base but also empowers teams to take ownership of process improvements. - Time Data Base as a Strategic Asset:
A robust Time Data Base is critical for advancing toward Industry 4.0 and 5.0. It serves as the foundation for digitalization, automation, and human-centric innovation, enabling data-driven decision-making and seamless integration of advanced technologies. - Alignment with Industry Trends:
By combining MTM with digital tools, we create a bridge between traditional process optimization and modern smart manufacturing. This approach supports:- Predictive analytics for better planning and resource allocation.
- Human-machine collaboration (Industry 5.0) to enhance productivity and innovation.
- Scalability to adapt to future technological advancements.
- Long-Term Impact:
This philosophy ensures that our improvement efforts are not just short-term fixes but sustainable strategies that align with evolving industry trends. It positions us to leverage digitalization for continuous growth and competitiveness.
What advice would you give to companies just starting their transformation journey? What are the key steps to take and pitfalls to avoid?
For companies beginning their transformation journey, here are key steps to take and pitfalls to avoid:
- Build the Right Team:
Assemble a diverse team that includes not only engineers but also frontline employees who deeply understand the product and processes. These individuals should be capable of performing the tasks themselves, ensuring practical and actionable insights. - Foster a Top-to-Bottom Culture:
MTM (Methods-Time Measurement) is not just a tool—it’s a cultural shift. Ensure buy-in from leadership while empowering employees at all levels to embrace the methodology. This creates alignment and drives sustainable change. - Start with Analysis, Follow with Action:
Begin by using MTM to analyze processes and identify inefficiencies. Once results and improvement scenarios are clear, have a dedicated implementation team ready to execute the changes. This ensures a smooth transition from planning to action. - Avoid Common Pitfalls:
- Lack of Training:Ensure all team members are properly trained in MTM to avoid misinterpretation of data or processes.
- Resistance to Change:Communicate the benefits of MTM clearly and involve employees early to build trust and engagement.
- Overcomplicating the Process:Start with small, manageable projects to demonstrate quick wins and build momentum.
- Focus on Continuous Improvement:
Transformation is not a one-time effort. Establish a culture of continuous improvement by regularly reviewing processes, celebrating successes, and learning from challenges.
By following these steps and avoiding common pitfalls, companies can lay a strong foundation for a successful transformation journey.
What business mistakes have you made in the past that provided you with the most valuable lessons, and how have you applied them to your development?
One of the most valuable lessons we’ve learned is the limitation of a vertical approach to process analysis. In the past, focusing solely on individual departments or steps often led to an incomplete understanding of the overall production or business. This approach resulted in lengthy analysis times, inefficiencies, and missed opportunities for improvement.
The shift to a transversal approach using MTM (Methods-Time Measurement) transformed how we operate. MTM’s aggregation philosophy allows us to:
- Identify and analyze multiple methods across the entire process, providing a holistic view.
- Reduce analysis costs by up to 80% by streamlining data collection and focusing on critical areas.
- Apply insights to both current production and new projects, ensuring continuous improvement and scalability.
This mistake taught us the importance of breaking down silos and adopting a collaborative, cross-functional mindset. By applying this lesson, we’ve not only improved efficiency but also fostered a culture of innovation and adaptability.
How do you prefer to spend your weekends when you want to disconnect from work and recharge your batteries?
When I want to disconnect and recharge, I love sailing at sea. There’s something incredibly freeing about being out on the water, where time is dictated by nature, and there’s no predetermined path—just the freedom to decide where and how to go.
Sailing also mirrors many aspects of work in a unique way:
- It requires planning and adaptability to navigate changing conditions.
- You have to solve problems in real-time, often with limited resources.
- It’s a team effort, where trust and collaboration are essential in a close, confined environment.
For me, it’s the perfect blend of adventure, challenge, and relaxation—a chance to reset while staying connected to the elements and the people around me.
What message would you like to convey to the potential attendees of your presentation, and what will be the greatest added value for them?
Whether you’re in manufacturing, services, or any other sector, MTM (Methods-Time Measurement) is a game-changer. It transforms how you manage your workforce, including indirect activities, and unites your entire organization under a common language.
By attending this presentation, you’ll discover how MTM can:
- Break down silos between departments like HR, Health & Safety, Quality, R&D, Production, and Methods.
- Optimize workforce efficiency by providing clear, data-driven insights.
- Foster collaboration across teams, ensuring everyone is aligned toward shared goals.
While LEAN activities focus on high efficiency by synchronizing the flow across the entire value stream, the MTM toolset enables optimal products (in terms of ease of installation ), workplaces and methods across the entire value chain.
Both determine success!
The greatest added value? You’ll leave with practical tools and strategies to drive measurable improvements in your organization, no matter your industry. Join us to unlock the full potential of your workforce and processes!
🌟 Join us at LEAN ACADEMY 2025 and gain firsthand insights from top Lean experts, including 🚀Emmanuel Calvez! 🚀
