The Importance of Capacity, Efficiency and Productivity (AQA A Level Business): Revision Note

Exam code: 7132

Lisa Eades

Written by: Lisa Eades

Reviewed by: Steve Vorster

Updated on

Using capacity efficiently

  • Efficiency means producing with the fewest possible resources

    • Using less time, labour, materials or energy

Why efficiency matters

  • Lower costs per unit

    • Spending less on inputs increases profit margins or allows lower selling prices to compete better with rivals

  • Higher competitiveness

    • Efficient firms can respond quickly to orders, which attracts and retains customer

  • Better use of resources

    • Cutting waste frees up cash and reduces a business's environmental impact, meeting both financial and sustainability objectives

Ways to use capacity efficiently

Way

Explanation

Example

Streamline the workflow

  • Put jobs and machines in the sequence they are done so items move forward, not back and forth

  • McDonald’s arranges its kitchens in a U shape

  • Burgers travel in one smooth line, cutting serving time

Invest in automation

  • Let robots, conveyor belts and machinery handle jobs people would otherwise do by hand

  • Amazon uses robots that fetch items from shelves for packers, speeding up each order and reducing walking time

Train staff

  • Teach staff to switch workstations and spot problems early, so the production line keeps moving when a worker is absent or a fault emerges

  • Starbucks baristas learn to make drinks, take payments and restock shelves, preventing delays at busy times

Introduce just‑in‑time (JIT) stock management

  • Have materials and components delivered right before use instead of storing weeks of stock

  • Toyota’s factories receive car seats hours before installation, saving warehouse space and cash

Preventive maintenance

  • Regular checks on machinery and carrying out small repairs stop big breakdowns that halt production

  • FedEx services its aircraft engines on a tight schedule, keeping planes flying and parcels on time

Difficulties increasing efficiency

  • Improving efficiency in production is not always easy

  • Difficulties can arise for a range of reasons

Why increasing efficiency can be difficult

Diagram showing "Difficulties of Increasing Efficiency" with four arrows pointing to issues: high upfront costs, quality and safety issues, employee resistance, supply chain issues.
Difficulties of increasing efficiency include employee resistance to change and high upfront costs

Difficulty

Why it makes efficiency gains hard

Example

High upfront cost of new equipment

  • Modern robots or faster machines can save money in the long run, but the initial cash outlay is large and risky—especially if sales are uncertain

  • Greggs shelved plans for fully automated sandwich lines in 2021

  • The £100 m cost was too high after the business suffered losses during the pandemic

Employee resistance to change

  • New methods may alter job roles or require fresh skills

  • Staff and trade unions can slow or block changes if they fear job cuts or tougher targets

  • Royal Mail faced strike threats when introducing automated sorting machines, delaying their introduction for several years

Supply‑chain bottlenecks

  • A factory cannot run faster if key parts or materials arrive late or in short supply

  • Ford repeatedly paused car production in 2021 because the global microchip shortage meant factories lacked these essential components.

Quality and safety trade‑offs

  • Increasing production speed without proper checks risks defects or accidents

  • Firms may have to slow back down to fix errors, wiping out any efficiency gains

  • Boeing accelerated 737 MAX assembly in 2018, but quality issues forced extra inspections and rework

  • This increased costs and delayed deliveries

Efficiency and labour productivity

  • Labour productivity is the amount of output each worker produces in a given period of time

    • Higher productivity means the same team turns out more products in the same working hours

  • Labour productivity is expressed in units and is calculated using the formula

Labour space productivity space equals space fraction numerator Total space output over denominator Number space of space workers end fraction

Worked Example

Green Man Fisheries prepares a wide range of high-quality seafood dishes that it sells to restaurants. Its most popular product is dressed crab.

Its 12 workers produced 1,404 boxes of dressed crabs in May. In June the business employed one more worker, and output increased to 1,677 boxes of crabs.

Calculate the change in labour productivity between May and June.

[3]

Step 1: Calculate labour productivity in May

May space equals space 1 comma 404 space boxes space divided by space 12 space workers

equals space 117 space boxes space per space worker (1)

Step 2: Calculate labour productivity in June

June space space equals space 1 comma 677 space boxes space divided by space 13 space workers

equals space 129 space boxes space per space worker (1)

Step 3: Calculate the difference

equals space 129 space boxes space minus space 117 space crabs

equals space 12 space boxes

  • Labour productivity has increased by 12 boxes per worker

  • Higher labour productivity leads to lower unit costs as long as wage rates remain the same

Worked Example

Each worker at Green Man Fisheries earns £2,000 per month.

Calculate the change in the unit cost of labour between May and June.

Step 1: Calculate labour costs for May and June

May space equals space 12 space cross times space £ 2 comma 000

equals space £ 24 comma 000

June space equals space 13 space cross times space £ 2 comma 000

equals space £ 26 comma 000 (1)

Step 2: Divide labour costs by output for May and June

May space equals space £ 24 comma 000 space divided by space 1 comma 404 space boxes

equals space £ 17.09 space per space box

June space equals space £ 26 comma 000 space divided by space 1 comma 677 space boxes

equals space £ 15.50 space per space box (1)

Step 3: Calculate the difference

equals space £ 17.09 space minus space £ 15.50

equals space £ 1.59 (1)

  • Unit cost of labour has reduced by £1.59 per box

Ways to increase labour productivity

Diagram illustrating ways to increase labour productivity: targeted training, better tools and technology, streamline processes, performance incentives.
Ways to increase labour productivity
  • Targeted training

    • Teach workers faster, safer or multi‑step techniques so they waste less time and make fewer errors

  • Better tools and technology

    • Give employees equipment that speeds up routine tasks

  • Performance incentives

    • Link pay or bonuses to clear output targets to encourage extra effort and focus

  • Streamline processes

    • Remove wasted steps so workers spend more minutes on value‑adding activity

      • E.g., Zara reorganised cutting and sewing stages so fabric moves straight to assembly

Difficulties increasing labour productivity

  • Low morale

    • Tired, stressed staff work more slowly, are absent more often and make more mistakes, limiting their productivity

  • Skill shortages

    • Better tools and methods only help if employees have the right skills

    • Recruiting or training skilled workers can be slow and expensive

  • Rigid work rules or union resistance

    • Employees' contracts may restrict task‑switching or new performance targets, reducing flexibility and slowing down change

      • E.g. London Underground’s plans to modernise stations has faced union action, delaying the introduction of multi‑skilled roles and new shift systems

  • Learning curve for new technology

    • Installing new software or machines can cut output at first while staff learn and early glitches are fixed

Capital and labour intensive production

  • Capital-intensive production mainly uses machinery and technology in the production of goods and services

    • Large-scale production of standardised products is likely to be capital-intensive

    • Manufacturing in developed countries where labour costs are relatively high is likely to be capital intensive

      • E.g. Car manufacturers such as Ford use robots and other production technology to manufacture vehicles, with supervisors overseeing the quality of output

  • Labour-intensive production mainly uses physical labour in the production of goods and services

    • The delivery of services is usually more labour-intensive than manufacturing

    • In countries where labour costs are low (e.g. Bangladesh) labour-intensive production is common

    • Small-scale production is likely to be labour-intensive

      • E.g. UK schools are labour-intensive operations as teachers plan and deliver lessons and provide pastoral support

Evaluating capital- and labour intensive production

Type of Production

Advantages

Disadvantages

Capital intensive

  • Low-cost production where output is high

  • Machines are usually consistent and precise

  • Machines can run without breaks

  • Significant set-up and maintenance costs

  • Breakdowns can severely delay production

  • May not provide flexibility in production

Labour intensive

  • Low-cost production where labour costs are low

  • Provides opportunities for workers to be creative

  • Workers are flexible (e.g. they can be retrained)

  • Workers may be unreliable and need regular breaks

  • Financial incentives may be needed to motivate staff

  • Training costs can be significant

You've read 0 of your 5 free revision notes this week

Unlock more, it's free!

Join the 100,000+ Students that ❤️ Save My Exams

the (exam) results speak for themselves:

Did this page help you?

Lisa Eades

Author: Lisa Eades

Expertise: Business Content Creator

Lisa has taught A Level, GCSE, BTEC and IBDP Business for over 20 years and is a senior Examiner for Edexcel. Lisa has been a successful Head of Department in Kent and has offered private Business tuition to students across the UK. Lisa loves to create imaginative and accessible resources which engage learners and build their passion for the subject.

Steve Vorster

Reviewer: Steve Vorster

Expertise: Economics & Business Subject Lead

Steve has taught A Level, GCSE, IGCSE Business and Economics - as well as IBDP Economics and Business Management. He is an IBDP Examiner and IGCSE textbook author. His students regularly achieve 90-100% in their final exams. Steve has been the Assistant Head of Sixth Form for a school in Devon, and Head of Economics at the world's largest International school in Singapore. He loves to create resources which speed up student learning and are easily accessible by all.