Implementation of Methods Engineering to Improve Occupational Safety and Productivity in the String-and-Button Envelope Manufacturing Process

Rachmad Santoso (Universitas Nusantara PGRI Kediri)
Elsanda Merita Indrawati (Universitas Nusantara PGRI Kediri)
Ary Permatadeny Nevita (Universitas Nusantara PGRI Kediri)
Kartika Rahayu Tri Prasetya Sari (Universitas Nusantara PGRI Kediri)
Hisbulloh Ahlis Munawi (Universitas Nusantara PGRI Kediri)
Venus Khatta Salsabillah (Universitas Nusantara PGRI Kediri)

Jurnal Manajemen dan Teknologi Rekayasa
Vol 5, No 2 (2026)

The high rate of occupational accidents in Small and Medium Enterprises (SMEs), particularly in the button map manufacturing process at PT. RR, is caused by unsafe rivet machine designs and risky work methods. This issue necessitates a feasible and integrated solution. A Methods Engineering approach was selected to combine technical and managerial interventions to create a safer working environment without sacrificing productivity. This study aims to: (1) analyze the effectiveness of rivet machine modifications in preventing accidents; (2) evaluate the impact of modified work methods on worker behavior and fatigue; and (3) measure the simultaneous balance between improved occupational safety and productivity. The research employs a mixed-methods quasi-experimental one-group pretest-posttest design. The stages include: (1) problem identification and baseline analysis; (2) design and implementation of interventions; (3) participatory worker training; (4) monitoring and data collection for three months post-intervention; (5) quantitative and qualitative data analysis; and (6) evaluation and conclusion formulation. The results demonstrate a significant improvement in operational performance, characterized by a 100% reduction in work accidents (from 5 to 0 incidents), the average cycle time decreased from 21.02 seconds to 18.75 seconds, representing a 10.80% improvement in time efficiency, this indicates a 12.1% increase in productivity, rising from 1,199 units/day to 1,344 units/day. Furthermore, there was a 43.44% reduction in the defect rate, dropping from 3.20% to 1.81%, which indicates an improvement in production quality resulting from the intervention. To examine the significance of these changes, a Paired T-test was conducted. The results show a t-stat of 48.63 with a p-value < 0.001 (below the threshold of p < 0.05). These findings provide strong empirical evidence that the implemented Methods Engineering intervention had a statistically significant impact on increasing production process speed.