Abstract: This study investigates the maximization of production efficiency in manufacturing environments by reducing cycle time and enhancing the productivity of workers. As manufacturing firms are always under pressure to remain competitive, there is a need to maximize operational efficiency at minimal capital outlays. This paper examines the effectiveness of various methods, including work split, workplace optimization, and inventory control, to reduce bottlenecks and maximize production throughput. A detailed inspection of a standard production plant revealed that an extra labour work-splitting method, where a high-bottleneck machine station was given an extra labour, raised output by 21%. Simulation further indicates that with other methods, such as improved inventory control and workstation redesign, the production output could be boosted by up to 30%. The study provides industrial advice to production businesses to reduce activities, cut down on cycle time, and maximize productivity by optimal deployment of man-force and improvement of the process.

Keywords: Cycle Time, Worker Productivity, Manufacturing Efficiency, Bottleneck, Work Split, Process Optimization, Lean Manufacturing.

| DOI: 10.17148/IARJSET.2025.12423