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 DC's 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 3 Oct 2022
• 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 SKU's planned for 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 - 155
  • Indirect (29):
    • Management - 7
    • Clerical - 10
    • Maintenance - 4
    • Janitorial - 4
    • Battery Changer - 2
    • Security - 2

• Direct:
  • Receivers - 35
  • Inventory - 6
  • Putaway/Replenishment drivers - 15
  • Pickers - 25
  • Shippers - 45

• 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 SKU's/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

1. Submit soft copy to Brightspace (D2L - Workforce Balancing AICE) by 11.59pm 7 Feb 2023, the plan is to be formatted in Excel. Expectations are that the report will detail:
   1. All calculations.
   2. Where your workers will be assigned to work.
   3. If you can meet the daily task, and if not, what trade-offs/actions are you prepared to make?

Remember, failure to achieve the daily task is not an option! Hiring staff or getting temporary workers is not an option; think about jobs you may have had - what happened when there was too much work, or someone called in sick, what did your Manager ask of anyone working?

Please ensure all group members are identified on the first page with SAIT registration numbers. Standard grading rubric for SCM Case Analysis applies.

Hours	Required	Workers	Shortfalll
15	360	280	80		1.82857143
15	64	120	-16
15	40
10	480	400	80
30	300	200	100
	1244	1000
15		90	244
			196

	Workload	Hours	Required	Workers	Shortfalll
Rec	20	10	200	280	-80
Put	1110	15	74	120	-16
Replen	450	15	30
Ship
Pick
Cycle Count