Workload Analysis to Determine Mechanical Workforce Requirements (Fulltime Equivalents) in Mining Projects: A Case Study of PT TMP

Abstract

The mining industry requires an optimal mechanical workforce to ensure equipment reliability, operational efficiency, and sustainable productivity. However, workforce allocation is often determined using conventional approaches that may not adequately reflect actual workload variations, resulting in potential overstaffing or understaffing. This study aimed to determine the optimal number of mechanical personnel required in the Asset Management Group (AMG) Department of PT TMP by applying the Full-Time Equivalent (FTE) method and integrating the results with Key Performance Indicators (KPIs), the Balanced Scorecard (BSC), Strategic Workforce Planning (SWP), and expert judgment. A quantitative descriptive approach was employed using historical maintenance data collected from April to December 2025, including work orders, maintenance duration, manpower requirements, and effective working hours. The workload was converted into FTE values, validated through expert judgment, and subsequently evaluated against departmental performance indicators. The findings revealed that the average ideal workforce requirement was 21.8 mechanics, with a peak demand of 39 mechanics, while the actual workforce averaged 37.9 mechanics. Nevertheless, expert validation recommended maintaining a workforce level of 45–48 mechanics as a strategic manpower buffer to accommodate operational uncertainties during the project transition period. Integration with KPIs demonstrated improvements in Physical Availability (98.6%), Mean Time Between Stoppages (118.3 hours), Mean Time to Repair (3.2 hours), and Manpower Cost per Hour (USD 5.66). The study concluded that integrating FTE analysis with performance management and strategic workforce planning provided a comprehensive, evidence-based framework for optimizing workforce allocation and supporting long-term operational sustainability in mining projects.