Workload Analysis Using the Full Time Equivalent Method to Determine the Optimal Workforce in the Sewing Section of CV Bebetrend Sukoharjo

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FORMOSA NEWS - Surakarta - Strategic Staffing Optimization Saves Garment Manufacturers Millions in Operational Costs. A research team at Universitas Duta Bangsa Surakarta revealed that adding six dedicated operators to overloaded workstations in garment production lines balances workloads and cuts monthly operating costs by nearly IDR 4 million compared to regular overtime reliance. The study was conducted by industrial engineering researchers Dimas Ilham Santoso, Indah Wahyu Utami, and Brillian Nur Diansari during the early 2026 research period. Published in July 2026, the investigation evaluates operator efficiency at CV Bebetrend Sukoharjo to address persistent production shortfalls. By demonstrating the financial and operational benefits of workload balancing, the findings offer industrial managers a practical blueprint to boost productivity while reducing employee fatigue.

Background and Context
The textile and textile products (TPT) industry serves as a crucial pillar of Indonesia's national economic growth. According to data from the Central Bureau of Statistics cited in the research, the manufacturing sector contributes 18 to 19 percent of Indonesia's Gross Domestic Product (GDP), with the garment industry absorbing approximately 3.75 million workers—representing 19.16 percent of the total manufacturing labor force. Within garment manufacturing, the sewing section is the most labor-intensive stage, requiring a large workforce alongside high dexterity, speed, and precision. When a mismatch occurs between the volume of work and the available workforce, overall operational efficiency drops. Unbalanced workloads cause severe production bottlenecks, high stress, operator fatigue, and reduced safety. At CV Bebetrend Sukoharjo, a garment manufacturer in Sukoharjo Regency, Central Java, the sewing section failed to achieve its daily production target of 400 pieces per line between January and March 2026. Actual monthly outputs dropped from 92.5 percent in January to 80 percent in March. This accumulation created daily shortfalls ranging from 30 to 80 pieces, translating to potential monthly production losses between 750 and 2,000 finished items.

Research Methodology
To resolve these production deficits, the researchers conducted an empirical workload analysis across all 10 workstations in the sewing section using the Full Time Equivalent (FTE) method. The team applied total sampling, analyzing all 10 active sewing operators. Primary data were gathered through direct observations, structured operator interviews, and precise stopwatch time study measurements. The methodology involved four distinct evaluation stages:

• Task Identification: Mapping every work element per workstation, including material positioning, component stitching, and final quality inspection.
  
• Time Measurement and Adjustment: Measuring cycle times using a stopwatch, verifying data sufficiency and uniformity, and applying the Westinghouse Rating Factor system to adjust for skill, effort, conditions, and consistency.
  
• Allowance Allocation: Adding a standard 15 percent allowance based on the International Labour Organization (ILO) framework to account for personal needs, sitting postures, continuous visual focus, and workplace noise.
  
• FTE Calculation: Converting adjusted standard times into annual workload values and dividing them by the annual available effective working time of 140,160 minutes (292 working days at 8 hours per day).
  

Under standard FTE metrics, values between 0 and 0.99 indicate underload, values between 1.00 and 1.28 indicate a normal workload, and values above 1.28 indicate an overload condition.

Key Findings
The study revealed two key operational insights:

• Workload Disparity: Four early-stage workstations operate within the normal capacity range (FTE 1.18–1.28) and consistently meet daily output targets. Six late-stage workstations suffer from significant overload (FTE 1.32–1.40) and fail to hit output goals.
  
• Financial and Personnel Impact: Relying on existing staff through 4.1 to 4.7 daily overtime hours per overloaded workstation costs the facility IDR 18,966,246 per month in overtime incentives. Hiring six additional operators to rebalance the stations costs approximately IDR 15,000,000 per month, yielding net monthly savings of IDR 3,966,246.
  

Real-World Impact and Industry Implications
This research demonstrates that expanding headcount in bottleneck areas yields higher cost efficiency than relying on systematic overtime. For manufacturing businesses, substituting overtime reliance with targeted hiring lowers labor expenses, prevents operator burnout, and maintains consistent daily output. Policymakers and industrial supervisors can utilize these findings to establish healthier labor standards in labor-intensive sectors. Furthermore, implementing cross-training programs allows operators at normal-capacity stations to support overloaded stations during peak demand periods.

Author Profiles
Dimas Ilham Santoso, S.T. is an industrial engineering researcher at Universitas Duta Bangsa Surakarta, specializing in manufacturing optimization, workload analysis, and labor productivity systems.
Indah Wahyu Utami, S.T., M.T. is a faculty member and researcher in the Department of Industrial Engineering at Universitas Duta Bangsa Surakarta, focusing on ergonomics, work design, and operational management.
Brillian Nur Diansari, S.T., M.T. is an industrial engineering lecturer at Universitas Duta Bangsa Surakarta with expertise in production planning, line balancing, and industrial engineering methods.

Source 
Dimas Ilham Santoso, Indah Wahyu Utami, Brillian Nur Diansari. Workload Analysis Using the Full Time Equivalent Method to Determine the Optimal Workforce in the Sewing Section of CV Bebetrend Sukoharjo. Formosa Journal of Sustainable Research (FJSR). Vol. 5, No. 7, Tahun 2026, Halaman 611-620
DOI : https://doi.org/10.55927/fjsr.v5i7.51
URL: https://journalfjas.my.id/index.php/fjas