<![CDATA[Air conditioning system maintenance is a vital activity to maintain the reliability of production facilities in the manufacturing industry. This study aims to evaluate and balance the workload of eight AC Maintenance technicians operating in tandem in four different work areas. Field observations were conducted using the Stopwatch Time Study approach with the shadowing method to measure the actual work duration, then analyzed using the Full-Time Equivalent (FTE) method. The initial evaluation results showed a significant workload imbalance between operators; two operators in Area 2 (Finishing Area) experienced overload with an average FTE index of 1.49 (149%), while two operators in Area 3 (Cast Coated Area) were underloaded with an average FTE of 0.92 (92%). Through repair simulation scenarios focused on eliminating waste and standardizing standard time per AC unit, activity duration inefficiencies were successfully reduced. Reducing wasted time by 6,452 minutes/month in Area 2 and absorbing the schedule overflow to Area 3 resulted in the normalization of all work areas to inload status (FTE 1.10-1.17). The underload conditions that emerged in Area 1 and Area 3 post-optimization were not directed at reducing the workforce, but rather were optimized through a job enlargement strategy in the form of routine 5S inspection activities, completing preventive maintenance checklists, and cross-area support functions. This study proves that workload balancing based on real-time data is able to produce optimal and balanced manpower allocation without adding or reducing personnel.]]>
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