Shift Scheduling Dilemma: How Many Extra Staff Do I Need for 24/7 Operations with Weekly Offs?

I want to run a machine 24/7 with 3 shifts and 4 manpower needed per shift to operate the machine. My question is, how many additional manpower do I need to recruit to provide weekly offs and other leaves?

Thank you.

Dear Atts-BU8,

Let the shift timings be 0800-1600 hours, 1600-2400 hours, and 2400-0800 hours.

Let the shift workers be named A, B, C, D, E, F, G, H, I, J, K, and L.

Let the standby workers be named P and Q.

Shift-wise Duty Roster

Day 0800-1600 1600-2400 2400-0800

Monday PBCD QFGH IJKL
Tuesday APCD EQGH IJKL
Wednesday ABPD EFQH IJKL
Thursday ABCP EFGQ IJKL
Friday ABCD EFGH PQKL
Saturday ABCD EFGH IJPQ
Sunday ABCD EFGH IJKL

The above information is also given in the attached Excel sheet. In each cell, a comment is provided about the worker's weekly schedule on a particular day and shift.

As per the above breakdown, we need at least 14 workers to run 24x7 operations in three shifts with four workers in each shift. However, this setup does not account for workers' sickness or earned leave. Therefore, we need to keep 1-2 workers on standby to cover their authorized or unauthorized absences. But what will these additional persons do when all the workers report for duty? Should they remain idle? To prevent their idleness, they need to be trained in maintenance work. These two persons will double up as maintenance technicians and shift workers.

Thanks,

Dinesh Divekar

To determine the additional manpower needed to provide weekly off and other leaves for a machine that runs 24/7 with three shifts, we need to know the total number of employees required to run the machine.

Assuming that each shift lasts for 8 hours, 4 manpower is needed for each shift. Therefore, the total number of employees required to run the machine is:

Total Employees = (4 manpower per shift) x (3 shifts) = 12 employees

Weekly Off:

Assuming each employee gets one weekly off every 7 days, you would need to hire 2 more employees to cover the missing workers during the weekly off. So the total number of employees required becomes:

Total Employees = 12 + 2 = 14 employees

Other Leaves:

Assuming each employee gets 10 days of other leave per year, you would need to hire additional employees to cover for the missing workers during these leave periods. One way to do this is to hire temporary workers or part-time workers who can fill in for the missing workers during their absence. The number of additional employees required depends on how many employees take leave at the same time.

For example, if you assume that one employee is on leave at any given time, you would need to hire 1-2 additional employees to cover for the missing worker. If you assume that two employees are on leave at any given time, you would need to hire 2-4 additional employees to cover for the missing workers.

Therefore, to give weekly off and 10 days of other leave per year, you would need to hire between 14 and 18 employees, depending on the number of employees on leave at any given time.

The exact number of additional manpower you will need to recruit to give weekly offs and other leaves depends on your business needs, the size of your workforce, and the number of employees already taking vacations or leaves. You will need to consider factors like the amount of available manpower you have to cover shifts and the workload of your staff. You may also need to consider the amount of overtime you are willing to pay to cover shifts, or the costs associated with hiring extra personnel. Ultimately, the decision on how many additional manpower you need to recruit will depend on your individual business needs.

Calculating Manpower Requirements for 24/7 Operations

3 shifts, 4 manpower per shift, and 7 days operation. Therefore, mandays required are 3 x 4 x 7 = 84.

One person with a weekly off has 6 mandays available per week. Therefore, for 84 mandays, 84 / 6 = 14 persons will be required with a weekly off.

Now, if we consider a 10% leave cover, then 10% of 14 will require another 2 persons.

Therefore, the total manpower required with a weekly off and 10% leave cover will be 14 + 2 = 16.

Regards, S K Bandyopadhyay (WB, Howrah) CEO-USD HR Solutions [Phone Number Removed For Privacy-Reasons] [Email Removed For Privacy Reasons] USD HR Solutions – To strive towards excellence with effort and integrity

Manpower Planning Formula

The straightforward formula for manpower planning is:
\[ \text{Manpower Planning} = \text{Sanctioned (X)} + 16.7\% \text{ of (X)} + \text{prevailing leave and absent \% of X} \]
\[ = 12 + 16.7\% \times 12 + \text{prevailing leave and absent \% of X} \]
\[ = 12 + 2 + \text{prevailing leave and absent \% of X} \]

If the prevailing leave and absent percentage of X is 10%:
\[ = 12 + 2 + 2 \]
\[ = 16 \]

If the prevailing leave and absent percentage of X is 5%:
\[ = 12 + 2 + 1 = 13 \]

High Sanctioned Manpower Scenarios

If sanctioned manpower is very high, like 50, 100, 200, 500, 1000, and more:
\[ \text{Manpower Planning} = \text{Sanctioned (X)} + 16.7\% \text{ of (X)} + \text{prevailing leave and absent \% of X} + \text{attrition \% of X} \]