Labour Productivity Calculator — Dairy Plant Output Per Man-Hour
Calculate labour productivity in dairy plants as output per man-hour or litres processed per employee per shift. Track and improve workforce efficiency.
What is Labour Productivity?
Labour productivity measures the output per unit of labour input in a dairy plant. It helps management understand how efficiently the workforce is being used and benchmark against industry standards.
Labour Productivity = Total Output / Total Man-Hours
Measured as: Litres per man-hour (L/man-hr) or kg product per employee per shift
How to Use This Calculator
- Enter total milk processed (litres or kg) in the period
- Enter number of employees on shift
- Enter shift duration in hours
- The calculator computes productivity, benchmarks against targets, and identifies efficiency gaps
Formulas
Litres Per Man-Hour
Productivity (L/man-hr) = Total Litres Processed / (Employees × Shift Hours)
Cost of Labour Per Litre
Labour CPL (₹/L) = Total Labour Cost / Total Litres
Labour Efficiency Index
LEI (%) = Actual Productivity / Target Productivity × 100
Example Calculation
A shift with:
- 25 employees over an 8-hour shift
- 50,000 litres processed
Productivity = 50,000 / (25 × 8) = 250 L/man-hour
If target is 300 L/man-hour:
LEI = 250 / 300 × 100 = 83.3% (room for improvement)
Industry Benchmarks
| Plant Type | Typical Productivity |
|---|---|
| Manual dairy (< 5,000 LPD) | 50–100 L/man-hr |
| Semi-automated (5,000–50,000 LPD) | 150–300 L/man-hr |
| Automated (50,000–200,000 LPD) | 300–600 L/man-hr |
| Highly automated (> 200,000 LPD) | 500–1,500 L/man-hr |
Factors Affecting Labour Productivity
| Factor | Impact |
|---|---|
| Automation level | Highest impact — 5–10× difference |
| Plant layout | Poor layout adds unnecessary movement |
| Downtime and breakdowns | Idle workers during stoppages |
| Training and skill level | Skilled workers are 30–50% faster |
| Shift scheduling | Fatigue in long or overnight shifts |
| Product mix | Complex products (cheese, UHT) need more labour |
Improving Labour Productivity
- Map process flows — identify unnecessary steps and travel
- Cross-train workers — flexibility reduces idle time
- Track attendance and idle time — data reveals inefficiency
- Automate repetitive tasks — filling, capping, labelling
- Set shift-level KPIs — daily productivity tracking with feedback