Operations Research and Lean 6S for Optimized Labor Allocation and Workforce Efficiency Under Absenteeism

Labour absenteeism remains a critical barrier to operational efficiency and workforce stability within the food manufacturing sector. This study presents a hybrid framework integrating Operations Research (OR) and Lean–6S methodologies to address labour allocation challenges in a real-world egg processing facility. The research focuses on the packaging zone the most labour-intensive and absenteeism-sensitive stage of production where a Binary Linear Programming (BLP) model was developed in Excel Solver to optimise employee assignments. The model allocates workers based on skill matrices, attendance availability, and role requirements while enforcing fairness constraints to prevent repetitive assignments and fatigue. Lean–6S and Standard Operating Procedure (SOP) audits were used to complement and evaluate organisational discipline, cleanliness, and process adherence, enabling a direct linkage between optimised labour deployment and workplace quality. Some of the key performance indicators, such as shortage-hours, Workforce Efficiency Index (WEI), 6S audit scores, and absenteeism rates, were quantitatively analysed before and after implementation. These Results indicate a measurable reduction in shortage-hours and reassignments, along with improved 6S and SOP compliance, validating the practical viability of the proposed system. The integrated framework establishes a data-driven relationship between workforce optimisation, quality adherence, and operational availability, thereby contributing to enhanced Overall Asset Effectiveness (OAE). This approach provides a scalable model for other food processing facilities seeking to balance efficiency, safety, and employee well-being under real-world labour variability.

Author dc:creator

• Akshay Uthaman (24399701)

• Operations Research
• Statisitical Quality Control

Statement dc:rights

• In Copyright

DOI dc:identifier

https://doi.org/10.25417/uic.32994179.v1

OAI identifier oai:identifier

oai:figshare.com:article/32994179