This study aimed to resolve conflicts between management and labor unions over staffing levels at a soft drink manufacturer in Sri Lanka. The researchers developed a new methodology combining scientific work design, manufacturing practices, and company culture. They applied this method to analyze staffing at two work centers. Results showed 25% excess staffing company-wide. After lowering staffing levels with union agreement, productivity increased without hindering process flow. The new approach created an environment where further improvements could benefit both management and workers.

1. The Impact of Work Design Concept on Manufacturing
Performance : A Process Sector Case Study
P. P. G. N. Vilasini, U. P. Kahangamage, J. R. Gamage & W. V. R. Kosala
BACKGROUND METHOD
This study presents findings from a case study carried out in a leading
Research plan
soft drink manufacturing company in Sri Lanka. It is a well-established
Initial Data Refine data Analysis Synthesis
large company with a mature workforce. The key objectives of the
study were to resolve a conflict between the company management investigation collection of data of model
and the labour union on manning levels of work centers of production
plant and to create conducive environment for overall productivity Feedback to participants
improvement of the company. Techniques used
The standard work design methods such as time study, activity Initial process
sampling and Method Time Measurement (MTM ) data were used for
this study. However, the nature of the company operation and the
presence of a strong labour union presented with numerous
challenges that prevented the direct use of those techniques. A Methods engineering
strategic method that combines the scientific management
approaches, work design concept and company operating practices
which blends with the unique culture of the company was developed Work measurement
to overcome those challenges. The results obtained from the Time study
Activity sampling
successful implementation of the developed methodology on two
MTM data
selected work centers of the company is presented. The method
presented can be extended to organizations with similar
characteristics.
Final process
RESULTS
Table 1 & 2 : Manning level analysis – Full bottle unloading and empty bottle loading work centers
Production in 000’s No. of Manning level
Production in 00’s No.of Cases/hr Manning level (bottle/hr) packs/hr Current Time study MTM
(bottle/hr) Current Time study MTM 10(100%) 1667 10-12 2.50[3] 4.3[5]
400 330 (100%) 1375 10-12 1.4 [2] 3.2[4] 8 (80%) 1334 10-12 2.00[2] 3.4[4]
ml 264 (80%) 1100 10-12 1.1[2] 2.5[3] 5 (50%) 834 10-12 1.25[2] 2.2[3]
250 360 (100%) 1500 10-12 1.5[2] 3.4[4]
ml
288 (80%) 1200 10-12 1.2[2] 2.8[3]
200 420 (100%) 1750 10-12 1.7[2] 4.0[4]
ml
336(80%) 1400 10-12 1.4[2] 3.2[4]
Table 3 : Efficiency improvements in selected work centres
Work centre Initial Final
efficiency efficiency
Full bottle unloading 25% 42% Figure 1: Generic
model for work
Empty bottle loading 42% 63%
design concept
CONCLUSION
The application of work design generic model that take into account unique culture of the company helped to reveal the non-value added
activities and idle time of worker groups during the production process. In general, there is around 25% excess labour in each production line.
Having considered the results and suggestions from the study, the management altered the manning levels of selected work stations on
experimental basis. The changes were done with a mutual understanding between the labour union and the management. It was proved that the
work centres with newly defined manning levels can be operated without any hindrance to the process flow even with a higher productivity. The
study created a conducive environment within the company to implement further productivity improvement activities that bring about benefits
for both company management and the workers.