Hilbram Ramadaniel Setiawan, Jaka Purnama

Analysis of Workforce Workload for Production Efficiency Improvement in Sandal Manufacturing Using Workload Analysis and Cardiovascular Load Methods

Introduction

Analysis of workforce workload for production efficiency improvement in sandal manufacturing using workload analysis and cardiovascular load methods. Boost sandal manufacturing efficiency. Analyze workforce workload and cardiovascular load (WLA, CVL) to optimize worker numbers, balance tasks, and improve production output.

Abstract

This study aims to analyse workforce workload and determine the optimal number of workers in the sandal production process at UD. Al Athyyah Mojokerto using the Workload Analysis (WLA) and Cardiovascular Load (CVL) methods. The company experiences workload imbalances across several production sections, resulting in bottlenecks and the inability to meet production demand. Average monthly demand reaches 5,000 pairs of sandals, whilst actual production only reaches approximately 4,700–4,800 pairs. Data collection was conducted through direct observation, interviews, and stopwatch time studies in the cutting, sewing, assembly, and finishing sections. The collected data were processed to calculate cycle time, standard time, workload percentage, and cardiovascular load values to evaluate both operational and physiological workload conditions. The results show that several workstations are categorised as overloaded, namely Cutting 1 (124%), Sewing 1 (106%), Sewing 2 (117%), Sewing 3 (108%), Sewing 4 (127%), Assembly 3 (102%), and Finishing 2 (105%). Meanwhile, several other activities were classified as underloaded. The CVL analysis indicates that most workers experience moderate to heavy physical workloads, particularly in the sewing and assembly sections, which may lead to worker fatigue and reduced productivity. Based on the analysis results, additional workers are required in overloaded workstations to achieve a more balanced workload distribution and improve production efficiency. The integration of WLA and CVL methods provides a comprehensive evaluation of workforce conditions and supports workforce planning in labour-intensive manufacturing industries.

Review

This paper presents a timely and relevant analysis of workforce workload in a sandal manufacturing setting, addressing a common challenge in labor-intensive industries: balancing operational efficiency with employee well-being. The study's objective to analyze workload and determine optimal staffing levels at UD. Al Athyyah Mojokerto is clearly articulated. A significant strength lies in its dual-methodology approach, integrating Workload Analysis (WLA) for operational assessment and Cardiovascular Load (CVL) for physiological evaluation. This comprehensive perspective aims to provide a more holistic understanding of workforce conditions, directly tackling issues of production bottlenecks and unmet demand stemming from workload imbalances. The research effectively combines quantitative and qualitative data collection, utilizing direct observation, interviews, and stopwatch time studies to calculate key metrics like cycle time and standard time. The findings from the WLA are precise, identifying specific workstations (e.g., Cutting 1, Sewing 4, Finishing 2) that are significantly overloaded, with percentages ranging from 102% to 127%. Complementing this, the CVL analysis reveals that most workers, particularly in the sewing and assembly sections, experience moderate to heavy physical workloads. This physiological strain is directly linked to potential fatigue and reduced productivity, underscoring the necessity of addressing both the operational capacity and the physical demands placed on workers. The study's conclusions strongly advocate for the addition of workers in the identified overloaded workstations to achieve a more balanced workload distribution, thereby improving production efficiency and enabling the company to meet its demand of 5,000 pairs of sandals monthly. The integration of WLA and CVL methods proves valuable in offering a robust foundation for strategic workforce planning within manufacturing. This research provides practical, actionable insights for similar labor-intensive settings, highlighting the critical link between workload management, employee health, and overall productivity. Future work could potentially explore the long-term impacts of implementing these recommendations and investigate specific ergonomic interventions beyond staffing adjustments.

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