Determining the Number of Workers Based on a Time-and-Motion Study to Meet Production Demand at the XYZ Tofu and Tempe Factory in Nabire

Abstract

One of the food industries that plays an important role in meeting community needs is the tofu and tempeh production industry. Therefore, this role must be supported by adequate infrastructure and workforce capacity to ensure that the production process runs effectively. This research determines the appropriate number of workers using a time-and-motion study to identify and eliminate unnecessary activities and establish standard working times for tofu production. The XYZ tofu and tempeh factory in Nabire has operated for approximately 10 years with six employees divided into two production sections: two workers for tofu production and four workers for tempeh production. A quantitative approach using direct stopwatch observation and the Westinghouse performance rating method was applied. The results show that the standard time for the entire tofu production process is 212.22 minutes, consisting of 177.73 minutes per box and an additional 34.49 minutes required only once at the beginning of production. Workload analysis indicates that the workload per worker decreases from 550.435 minutes with two workers to 485.443 minutes with three workers, while daily output increases from six to eight boxes of tofu. The improvement scenario involving three workers producing eight boxes results in a monthly wage cost of IDR 4,500,000 and an income of IDR 118,380,000, making it more profitable than the scenario with two workers (32.7% lower productivity) and the overtime scenario with two workers (0.36% lower productivity). These findings imply that adding one worker represents the most optimal policy for the factory to meet consumer demand without overburdening existing employees.