Enter MODAPTS® (Modular Arrangement of Predetermined Time Standards), a work measurement system designed to root out waste at the micro level. While some see MODAPTS® as just a time study tool, those using it strategically know it’s much more: a framework that directly targets the hidden costs undermining productivity.
In this article, we’ll explore exactly how MODAPTS® helps manufacturers eliminate these silent profit killers — and why now is the time to get serious about its implementation.
Understanding Hidden Costs in Manufacturing
Before we dive into MODAPTS®, let’s name the enemy. Hidden costs in manufacturing can take many forms:
- Inefficient motions and wasted movements that slow cycle times
- Overproduction due to inaccurate labor standards
- Excess overtime caused by misaligned work planning
- High ergonomic risk leading to injuries and absenteeism
- Training costs tied to inconsistent work methods
- Quality defects resulting from operator fatigue or poor workflows
While each of these may seem minor in isolation, collectively they erode profitability. Worse yet, they often go unmeasured and unmanaged — because they’re baked into daily operations. This is where MODAPTS® steps in.
What Is MODAPTS® and How Does It Work?
MODAPTS® is a predetermined time system (PTS) that assigns standard time values to basic human movements. Unlike stopwatch time studies, which record how long a task takes, MODAPTS® breaks work into measurable motion elements — each with an assigned time value.
For example:
- Reach, grasp, move, position, release — each motion has a modular time unit
- MODAPTS® codes represent combinations of these actions
- By summing the modules, you calculate the standard time for the task
This structured approach brings scientific rigor to labor measurement while remaining simple enough to apply on the shop floor.
1. Eliminating Inefficient Motions and Wasted Movement
The first hidden cost MODAPTS® attacks is excess motion. By breaking work into elemental motions, MODAPTS® makes it glaringly obvious when operators are:
- Reaching too far
- Walking unnecessarily
- Handling parts multiple times
- Performing awkward or excessive movements
Using MODAPTS® codes, engineers can pinpoint exactly where movements should be reduced or streamlined. Over time, this leads to:
- Shorter cycle times
- Reduced worker fatigue
- Smoother, more efficient workflows
In other words, MODAPTS® transforms the invisible — wasted motion — into something measurable and actionable.
2. Setting Accurate Labor Standards
Inaccurate labor standards are a massive hidden cost. Overestimate, and you overstaff and overproduce. Underestimate, and you strain your workforce, leading to errors and overtime.
MODAPTS® fixes this by providing objective, consistent standards based on physical reality — not stopwatch averages or subjective estimates. This brings multiple cost-saving benefits:
- Balanced lines that avoid bottlenecks
- Optimized staffing levels
- Reduced need for overtime
- More predictable production planning
The result? Less waste, less chaos, and more control over your labor spend.
3. Cutting Excess Overtime and Labor Costs
Manufacturers often bleed money through excessive overtime — a symptom of poor work planning and mismatched labor standards. MODAPTS® helps eliminate this by aligning planned work time with actual operator capabilities.
When you standardize tasks using MODAPTS®, you can:
- Accurately forecast how many operators are needed
- Avoid last-minute staffing shortages
- Prevent burnout from chronic overtime
Reducing overtime doesn’t just lower direct labor costs — it also curbs indirect costs like turnover, absenteeism, and injury claims.
4. Reducing Ergonomic Risk (and Related Costs)
Ergonomic injuries are one of the most expensive hidden costs in manufacturing, leading to workers’ compensation claims, absenteeism, and lost productivity.
Because MODAPTS® breaks work into motion categories, it also serves as a proactive ergonomic risk assessment tool. By identifying high-risk movements (like excessive bending, twisting, or heavy lifts), MODAPTS® allows manufacturers to redesign tasks before injuries occur.
Fewer injuries = fewer claims, lower insurance premiums, and a healthier, more productive workforce.
5. Streamlining Training and Onboarding
Training costs are often underestimated. Inconsistent work methods mean longer onboarding times, more mistakes, and slower ramp-ups.
With MODAPTS®, you establish standardized, repeatable work instructions based on optimized motion patterns. This simplifies training by:
- Giving new hires clear, consistent task guidelines
- Reducing the learning curve
- Improving early-stage productivity
When every operator is trained to the same high standard, variability drops — and efficiency rises.
6. Preventing Quality Defects
Quality issues often trace back to overworked, fatigued operators or chaotic, inefficient workflows. MODAPTS® mitigates this risk by ensuring tasks are designed for optimal flow and manageable workload.
- Less fatigue reduces errors
- Standardized motions prevent inconsistencies
- Balanced lines reduce rush and stress
The outcome: lower scrap rates, fewer reworks, and stronger customer satisfaction — all significant but often hidden contributors to cost.
Why Now Is the Time for MODAPTS®
With labor shortages, rising wages, and global competition tightening the screws on manufacturers in 2025, the need to root out hidden costs has never been greater. MODAPTS® offers a scalable, proven method to:
- Gain visibility into inefficiencies
- Optimize labor without overburdening staff
- Drive sustainable productivity gains
Unlike tech-heavy solutions that require massive investment, MODAPTS® is a low-cost, high-impact system that delivers quick wins while supporting broader Lean and continuous improvement goals.
Getting Started: Bring MODAPTS® Into Your Plant
Whether you’re running a high-volume assembly operation or a low-volume, high-mix facility, MODAPTS® can adapt to your needs. To get started:
- Train key staff in MODAPTS® coding and analysis
- Audit critical tasks for wasted motions and inefficiencies
- Redesign workflows based on MODAPTS® data
- Standardize work instructions for training and quality
Need help? Eisbrenner Productivity Group specializes in implementing MODAPTS® systems tailored to your operation. Our experts can guide your team through training, analysis, and sustainable improvement.
Conclusion
Hidden costs are the silent killers of manufacturing profitability. MODAPTS® shines a light on these inefficiencies and provides the tools to eliminate them — from wasted motion to inaccurate labor standards, excessive overtime, ergonomic risks, training overhead, and quality defects.
By adopting MODAPTS®, manufacturers don’t just measure work — they transform it. The result is a leaner, healthier, and more profitable operation.
Ready to uncover the hidden costs holding your plant back? Contact Eisbrenner Productivity Group today to learn how MODAPTS® can drive your next productivity breakthrough.