SYNERGIZING LEAN MANUFACTURING AND MAYNARD OPERATIONAL SEQUENCE TECHNIQUE FOR ENHANCED LABOR PRODUCTIVITY IN SYNTHETIC FIBER MANUFACTURING

Abstract

In the era of Industrial Revolution 4.0, manufacturing sectors face intense competition requiring companies to consistently meet customer demands. However, labor-related process delays increasingly hinder timely delivery and reduce overall productivity. This study aims to improve workplace productivity by conducting a time study to establish standard times as a baseline for identifying activities while capturing inefficiencies and non-value-added tasks to support leaner processes and sustainable labor utilization. A case study was conducted in a synthetic fiber manufacturing facility, focusing on direct labor activities at critical processes. Lean Value Stream Mapping (LVSM) and the Maynard Operational Sequence Technique (MOST) were applied in line with the standard work procedures. MOST, known for enhancing productivity with minimal capital investment, was validated against video-recorded observations, with a t-test confirming results at 95% confidence level. The analysis identified significant improvement opportunities, particularly among packaging operators (highest utilization) and winding operators (lowest utilization). Implementation of targeted actions improved labor productivity by over 20%, exceeding management’s initial target. Hence, this case study provides empirical evidence of the effectiveness of MOST in real-world manufacturing and offers practical insights for organizations seeking to optimize labor efficiency in competitive industrial environments.