In-Class Exercise

Workforce Balancing

Task

1.This is an In-Class assignment, which will be assessed (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 DC's 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 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 SKU's 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

• Volumes - reasonably constant, seasonal 20% peaks in Apr/May and Oct/Nov.
• Material Handling Equipment:
• Pallet 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 person-hours per container.
• Outbound Shipping - 200 store shipments per week, productivity 10 person-hours per shipment.

Report

2.Submit soft copy to Brightspace (D2L - Workforce Balancing AICE) by 11.59pm 12 Feb 2021, the plan is to be formatted in Excel. Expectations are that the report will detail where your workers will be directed to work and if you can meet the daily task.If not, what trade-offs are you prepared to take?Identify any shortfalls and explain why your allocation of direct workers is the best option.Tip: Think about the flow through the facility.