Workforce Balancing

Task

1. This is an individual assignment worth 3%. 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 all direct workers can be employed in any of the direct areas. Develop a workforce plan to best satisfy the daily workload with the direct labour provided.

Scenario

• The date is 5 Mar 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 SKUs require Cycle Counting

• Sector Retail
• Operating hours 2 shifts, 8 hours a day Mon-Fri, 7.30am 11.30pm. Assume that the workforce is split equally between the 2 shifts.
• Staff 170
  • Indirect:
    • Management - 7
    • Clerical - 11
    • Maintenance - 4
    • Janitorial - 4
    • Battery Changer - 2
    • Security - 2
  • Direct:
    • Receivers 35
    • Putaway/Replenishment drivers 15
    • Pickers 30
    • Shippers - 55
    • Inventory - 5

• Productivity
  • Pallet Putaway productivity 15 pallets/hour (taking full pallets from receiving area to pallet racks)
  • Pallet Replenishment productivity 15 pallets/hour (pulling full pallets out of racks onto the floor picking locations)
  • Picking productivity 30 picks/hour (picking to shipping for customers)
  • Inventory Count productivity 15 SKUs/hour
  • Inbound Receipts 100 floor-loaded containers per week, or 15 person-hours per container. (unloading a truck)
  • Outbound Shipping 200 store shipments per week, or 10 person-hours per shipment. (loading a truck)

HbAutoSave Off Workforce Calculator O Search (Alt+Q) Sarah Nkoli SN 7 File Home Insert Page Layout Formulas Data Review View Help Share Comments Insert LO Calibri 11 ' = = a Wrap Text General 47 9X Delete WOO Paste BIU a. Av A y Es Merge & Center 5 + $ % -28 , v Conditional Format as Cell Formatting Table Styles Styles Format Sort & Find & Filter Select Fm Analyze Sensitivity Data Analysis Sensitivity Clipboard Font Alignment Number Cells Editing A 04 fac u K L L M N o P Q Workers Work Planned Assigned (units) 6 960 Units Diff Diff % Over or Under Comments -4% Added 1 worker from... -40 B D E F G . H 1 1 given 2 calculate enter 8 hrs per worker Work Units Required Required Workers Worker 3 Area Productivity Required Hours Workers Available 4 Example 20 picks/hr 10000 50 6.25 5 5 -1.25 5 Pallet Putaway 6 Pallet Replenishment 7 Picking 8 Inventory count 9 Inbound Receipts 10 Outbound shipping 11 Balance Balance Balance Extra Comments 12 13 14 15 16 17 18 19 20 21 + Work Balancing Calc Ready Accessibility: Investigate Type here to search 100% j E -24C Mostly sunny ENG 10:01 AM 2/2/2022 F HbAutoSave Off Workforce Calculator O Search (Alt+Q) Sarah Nkoli SN 7 File Home Insert Page Layout Formulas Data Review View Help Share Comments Insert LO Calibri 11 ' = = a Wrap Text General 47 9X Delete WOO Paste BIU a. Av A y Es Merge & Center 5 + $ % -28 , v Conditional Format as Cell Formatting Table Styles Styles Format Sort & Find & Filter Select Fm Analyze Sensitivity Data Analysis Sensitivity Clipboard Font Alignment Number Cells Editing A 04 fac u K L L M N o P Q Workers Work Planned Assigned (units) 6 960 Units Diff Diff % Over or Under Comments -4% Added 1 worker from... -40 B D E F G . H 1 1 given 2 calculate enter 8 hrs per worker Work Units Required Required Workers Worker 3 Area Productivity Required Hours Workers Available 4 Example 20 picks/hr 10000 50 6.25 5 5 -1.25 5 Pallet Putaway 6 Pallet Replenishment 7 Picking 8 Inventory count 9 Inbound Receipts 10 Outbound shipping 11 Balance Balance Balance Extra Comments 12 13 14 15 16 17 18 19 20 21 + Work Balancing Calc Ready Accessibility: Investigate Type here to search 100% j E -24C Mostly sunny ENG 10:01 AM 2/2/2022 F