How Can Assembly Processes Be Objectively Evaluated Already in the Concept Phase – Even Before Real Workstations Exist?
This was the challenge FESTO faced when new production systems were planned and existing assembly processes were revised. The goal was clear: not only to plan motion sequences visually, but to evaluate them quantitatively in early phases to enable well-founded decisions. For this purpose, FESTO used Halocline Professional in combination with the MTM Add-On & MTMmotion®.
This made it possible to capture real work movements in the virtual environment, analyze them automatically, and compare variants using MTM time values – all without traditional time studies. FESTO was thus able to identify optimization potential early on and reliably assess process variants.
FESTO planned new production systems and wanted to evaluate layouts and process flows already in early phases – not only based on space, ergonomics, and material flow, but also using time metrics. In previous projects, process time analysis was often only possible in later phases, once complex time studies were available or experts had been consulted.
The goals were:
- Make different variants comparable not only visually but also in terms of time
- Identify bottlenecks and inefficient motion sequences early
- Make decisions on a data-driven basis already in the concept/layout phase
- Avoid additional effort from manual time studies
With Halocline Professional and the MTM Add-On, FESTO was able to systematically address these goals.
Approach
Step 1: Prepare Objects and Define Usage Types
Before a process recording begins, the interactive objects must be prepared so that Halocline can correctly detect and classify their movements.
FESTO therefore started with carefully configuring the objects in the desktop view.
- Interactive objects (components, tools, parts) are marked in the model.
- Via the context menu, each object receives an object type ID and a usage type ID – e.g., “grasp workpiece” or “place component.”
- If relevant, the object’s weight is entered so that MTMmotion® can account for force and recovery components.
- For automated operations, fixed process times can be stored to replace manual recording.
→ More in the workflow: Layout Planning – Designing Efficient Workflows
Step 2: Record the Process Flow in VR (Halocline Performance)
After preparing the objects, FESTO switches to the virtual environment to recreate real action sequences.
The recorded movements form the basis for the MTM analysis.
- FESTO uses the Performance Mode to simulate process steps in VR.
- Each interaction with an object is triggered and logged.
- When an object is inserted into another, it releases automatically; other actions require intentional placement.
- All motion and interaction data are saved and linked to the defined usage types.
This results in a precise motion recording that captures all motion sequences and hand movements.
→ More in the workflow: Layout Planning – Designing Efficient Workflows
Step 3: Export and Upload to the Web Portal
Once all sequences are recorded, the data is transferred to the MTMmotion® web portal.
This is where the actual MTM evaluation takes place.
- In the replay window, the export is started via “Export → MTM”.
- Halocline creates a json file stored in the user directory.
- FESTO uploads this file to the json web portal.
- The desired MTM system (e.g., MTM-UAS, MTM-HWD, or MTM-1) and the time unit (TMU or seconds) are selected there.
- The portal analyzes the movements, assigns MTM motion codes, and generates a structured time assessment.
FESTO thus obtains reliable MTM times for process variants – already in the concept phase.
→ More in the workflow: Using MTM Time Evaluation Already in Early Phases
Step 4: Analysis, Comparison, and Optimization
With the results from the MTM evaluation, the optimization phase begins. FESTO can now compare variants and make targeted adjustments before physical tests become necessary.
- Multiple variants are simulated, exported, and analyzed in VR.
- The MTM time values reveal where unnecessary movements, non-ergonomic gripping motions, or time-intensive sequences occur.
- Based on these insights, layouts or motion sequences are adjusted.
- Each revised variant is re-recorded and evaluated until the most efficient solution is identified.
This creates a transparent, data-driven improvement process.
→ More in the workflow: Using MTM Time Evaluation Already in Early Phases
Results and Added Value for FESTO
By using Halocline Professional and MTMmotion®, FESTO was able to significantly improve and accelerate its process planning:
- Early, reliable time data already in concept and layout phases
- Objective variant comparison based on MTM times
- Identification of bottlenecks and unnecessary movements
- Reduced planning times through direct simulation and evaluation
- Well-founded decisions without additional time studies
- Seamless integration into the existing Halocline planning process
Conclusion
The FESTO case shows how Halocline Professional with MTM Add-On enables the transition from visual planning to quantitative process evaluation. The combination of VR simulation and MTM analysis produces valid time data already in early phases, allowing variants to be compared objectively and processes to be optimized in a targeted manner.
This transforms traditional layout planning into a data-driven, efficient, and traceable planning process – validated by MTMmotion®.