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 labor 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.
Strategic Takeaway
- The key staffing question is not how many people, but matched to what load.
- Data-based staffing survives peak demand cycles better than intuition-based staffing.
Contact Gemba Concepts
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