Relationship between Absenteeism and Productivity: Performance, Variability, and Process Robustness Using Lean Manufacturing Tools

Abstract

Work absenteeism is a critical external factor that affects the performance, stability, and robustness of manufacturing systems, particularly in labor-intensive assembly processes. The unplanned absence of operators alters standard operating conditions, reduces the effective capacity of the system and introduces uncontrolled variability, which generates imbalances in workload, increases in cycle times, bottlenecks, and decreased productivity. This variability deteriorates the stability of the system, increases waste, and negatively affects on-time delivery. While traditional literature has addressed absenteeism from organizational and psychosocial perspectives, recent research highlights the need to analyze it from an operational and quantitative approach, considering its direct impact on process variability and statistical stability. In this context, absenteeism acts as a recurring external disturbance that tests the productive system's ability to maintain consistent performance. Line balancing has the potential to mitigate the effects of absenteeism by decreasing dependence on specific operators and increasing operational flexibility. Integrated within structured continuous improvement methodologies, such as DMAIC, line balancing can be systematically evaluated in terms of its impact on process variability, productivity, and robustness. This research analyzes the relationship between work absenteeism and productivity in an industrial assembly process and evaluates its effectiveness as a strategy to reduce variability induced by staff absences. With the application of DMAIC and statistical tools such as control charts, regression analysis, time studies, and hypothesis testing, the results show a negative and statistically significant relationship between absenteeism and productivity, as well as a substantial reduction in variability following the implementation of line balancing.