KIE Factory Stories: Why Did the HR Manager Refuse to Hire More Workers?

“We need six more operators. Otherwise, we will miss the monthly target.”

The Production Manager was frustrated.

Orders were increasing, overtime was rising, and the team was struggling to keep up.

HR started preparing the recruitment plan.

But before approving it, the HR Manager asked to observe the production line.

She watched one operator walk across the workstation to collect parts.

Another operator waited for a tool.

A third operator kept leaving the station to bring empty containers back.

“Are these people short of work?” she asked.

“No,” said the Production Manager. “They are short of time.”

She watched a little longer.

The operators were busy.

But much of that busy time was spent walking, waiting and searching.

The team rearranged the parts, moved the tools closer and changed how empty containers were collected.

They measured the output again.

The line was producing more with the same team.

Six new hires were no longer needed.

This is a key lesson in manpower planning and industrial engineering.

Before adding people, check whether the existing process is wasting their time.

More workers cannot always solve a problem created by poor workplace design.

Don’t calculate manpower only from how much work you see.

First, remove the work that should never have been there.