Improving manpower utilization through work-study and lean techniques: A case of manual assembly

Abstract

Despite technological advances, many manufacturing industries continue to rely on manual assembly lines. However, manual assembly lines often experience situations of underutilized manpower due to inefficient workload distribution and suboptimal work methods. The ability to optimize manpower utilization in labour-intensive operations remains a decisive factor in sustaining operational efficiency while contributing to better workforce morale and engagement. This paper presents a case report of optimizing manpower utilization in a manual assembly process in Sri Lanka. The main objectives of the study were to investigate the current state of manpower utilization in the manual assembly process and optimize the manpower utilization using work study and lean techniques. These objectives well align with Sustainable Development Goals (SDGs) of Decent Work and Economic Growth (SDG 8), Industry, Innovation and Infrastructure (SDG 9), and Responsible Consumption and Production (SDG 12). Through systematic analysis of work methods and time measurement data, this study developed an evidence-based framework for manpower optimization. The findings provide an essential understanding of the interconnected impact of work method inefficiencies and workload imbalances on manpower utilization. This led to the optimization of manpower utilization through improved work methods and workload re-distribution without altering the plant's existing level of automation to create more efficient and sustainable production processes with increased worker well-being. Overall, the holistic methodology adopted in the study can be replicated to optimize manpower utilization in numerous contexts across different types and sizes of organizations.

Improving Learning of Green's Functions Through Kernel Decomposition
Beiji Chen, Qiang Du, Kui Ren +1
arXiv6 Oct 2026PreprintarXiv licenceFull textAnalysis & PDEs Numerical analysis & scientific computingarXiv
Improving Hydrofoil Efficiency Through Simulation-Driven Design Optimization
Ante Sikirica, Ivana Lučin, Marta Alvir +1
arXiv4 Nov 2026PreprintCC BY 4.0Full textOptimisation & controlarXiv
Improving ecological inference and uncertainty quantification from camera trap data through the fusion of AI confidences and manual annotations
Adira Cohen, Erin M. Schliep, Mohammad Alyetama +2
arXiv14 Oct 2026PreprintarXiv licenceFull textStatisticsarXiv
Key challenges and bridges among convergence analysis techniques for polytopal methods
Lourenço Beirão da Veiga, Daniele A. Di Pietro, Jérôme Droniou
HAL22 May 2026PreprintLicence not statedNumerical analysis & scientific computingHAL
Une étude des pratiques enseignantes dans la formation des futurs techniciens en statistique : le cas des techniques de sondage en BUT Science des Données
Camille Doukhan, Charlotte Derouet, Antoine Rolland +2
HAL30 Sep 2026PreprintPublisher termsFull textStatisticsHAL

Cite

BibTeX RIS

BibTeX

@article{abesinghe2026improving,
  title = {{Improving manpower utilization through work-study and lean techniques: A case of manual assembly}},
  author = {Nethmi Abesinghe and Kumuduni Hennayaka and Ayesha Malshani and Chaminie Ranahansi and Priyasha Ranathunga and Vathsala Wickramasinghe and Prasanna Illankoon},
  journal = {WPOM-Working Papers on Operations Management},
  year = {2026},
  month = sep,
  doi = {10.4995/wpom.25746},
  url = {https://hal.science/hal-05752507v1},
  note = {CC BY-NC-SA 4.0},
}

RIS

TY  - JOUR
TI  - Improving manpower utilization through work-study and lean techniques: A case of manual assembly
AU  - Nethmi Abesinghe
AU  - Kumuduni Hennayaka
AU  - Ayesha Malshani
AU  - Chaminie Ranahansi
AU  - Priyasha Ranathunga
AU  - Vathsala Wickramasinghe
AU  - Prasanna Illankoon
PY  - 2026
DA  - 2026/09/14
JO  - WPOM-Working Papers on Operations Management
DO  - 10.4995/wpom.25746
UR  - https://hal.science/hal-05752507v1
AB  - Despite technological advances, many manufacturing industries continue to rely on manual assembly lines. However, manual assembly lines often experience situations of underutilized manpower due to inefficient workload distribution and suboptimal work methods. The ability to optimize manpower utilization in labour-intensive operations remains a decisive factor in sustaining operational efficiency while contributing to better workforce morale and engagement. This paper presents a case report of optimizing manpower utilization in a manual assembly process in Sri Lanka. The main objectives of the study were to investigate the current state of manpower utilization in the manual assembly process and optimize the manpower utilization using work study and lean techniques. These objectives well align with Sustainable Development Goals (SDGs) of Decent Work and Economic Growth (SDG 8), Industry, Innovation and Infrastructure (SDG 9), and Responsible Consumption and Production (SDG 12). Through systematic analysis of work methods and time measurement data, this study developed an evidence-based framework for manpower optimization. The findings provide an essential understanding of the interconnected impact of work method inefficiencies and workload imbalances on manpower utilization. This led to the optimization of manpower utilization through improved work methods and workload re-distribution without altering the plant's existing level of automation to create more efficient and sustainable production processes with increased worker well-being. Overall, the holistic methodology adopted in the study can be replicated to optimize manpower utilization in numerous contexts across different types and sizes of organizations.
SN  - 1989-9068
SN  - 1989-9068
ER  -

Abstract

Related

Cite