Group In-Class Exercise

Workforce Balancing

Task

1. This is a group In-Class assignment, which will be assessed (2%). In your group, you are required to produce a workforce plan to best achieve the daily production schedule, in the detailed scenario below. The information provided in the DC Design Exercise provides the background of the DCs volumes and operational information. Assume that the DC has implemented a training schedule of cross-training, and direct workers can be employed in any of the direct areas. Develop a plan to achieve the daily workload.

Scenario

• The date is 5 Mar 2021
• The workload for the day has just been announced:
  • 24 Containers need to be unloaded
    • 960 pallet Putaways
  • 48 Store shipments deadline for meeting the transportation cut-off is 11.59pm.
    • 9,000 Picks
    • 600 Pallet Replenishments from storage to pick location
  • 500 SKUs require Cycle Counting

• Sector Retail
• Operating hours 2 shifts, 8 hours a day Mon-Fri, 6.30am 11.30pm. Assume that the workforce is split equally between the 2 shifts.
• Staff 160
  • Indirect:
    • Management - 7
    • Clerical - 10
    • Maintenance - 4
    • Janitorial - 4
    • Battery Changer - 2
    • Security - 2
  • Direct:
    • Receivers 35
    • Putaway/Replenishment drivers 15
    • Pickers 25
    • Shippers - 50
    • Inventory - 5
• Volumes reasonably constant, seasonal 20% peaks in Apr/May and Oct/Nov.
• Mechanical Handling Equipment:
  • Pump Jacks 10
  • Single pallet Walkies 20
  • Double pallet Walkies 10
  • Forklift Trucks - 15
• Pallet Putaway productivity 15 pallets/hour
• Pallet Replenishment productivity 15 pallets/hour
• Picking productivity 30 picks/hour
• Inventory Count productivity 15 SKUs/hour
• Inbound Receipts 100 floor-loaded containers per week, productivity 15 man-hours per container.
• Outbound Shipping 200 store shipments per week, productivity 10 man-hours per shipment.

Report

Expectations are that the report will detail where your workers will be directed to work and if you can meet the daily task, and if not, what trade-offs are you prepared to take?.