Rs 1.67 Crore a Year, from Staffing Decisions Made on Data

The Situation

Workforce allocation was governed by department habit, with limited time-study evidence to challenge legacy staffing.

Some machines ran underloaded while associated manning remained unchanged.

Recurring labour cost was visible in accounts but lacked operational cause visibility.

What We Did

We linked manpower to actual workload, not precedent, and redesigned flow where needed.

• Executed department-wise time studies.
• Applied Yamazumi balancing across stations.
• Introduced cellular manufacturing to tighten movement and handoffs.
• Decommissioned underutilized machines and associated excess manning.

The Results

Manpower cost reduced 11% over 15 months, translating to roughly Rs 1.67 crore annual savings.

The organization now makes workforce decisions on data, improving resilience through demand cycles.