Manpower Requirement Calculation

Manpower requirement calculation is now a vital part of all manufacturing industry in this competitive world. Because it will help to invest your money wisely. In this article we will explain how to calculate manpower required for a manufacturing industry with example.

Download manpower requirement calculation Excel Template

The Calculation

The formula in the picture gives the manpower required per shift for producing n no of products per day. t is the total standard man minutes required for producing one unit. w is the working time of an employee per shift and s is the no of shifts per day.

Note: Please note that this formula is only applicable where enforced idle of the operator is not present in the operation. Enforced idle means the operator is forced to be idle due to some other reasons of his working environment. For example, some operators of the balanced assembly line will be idle to some extend, especially the operator at the operation which has the lowest cycle time, waiting for his turn. This is not avoidable because we cannot balance the assembly lines at 100% perfect.

For calculating manpower for balanced assembly line there is another method and click the below button to know more.

Coming back to our basic manpower calculation…

Also in this calculation it is assumed that every operator is skilled for every operation and they are ready to do all operation whenever needed. In this calculation method its assumed that operators move around workstations to do operations and to avoid the Idle time.

This calculation is applicable where product demand is varying, for constant demand we should set an balanced assembly line.

For varying demand and low volume high mix production, this is the only method to achieve higher manpower efficiency. But requires highly skilled supervision to allocate operators to the process.

And manpower allocated through this method will be the minimum possible than other method, with same cycle time.

Importance of efficiency in manpower requirement calculation

Its better to consider 85% efficiency in the manpower calculation for getting the practical results. This efficiency is accounted for loses such as power failure, material shortages, speed loses, rework, defects, etc. If efficiency of your operation is better or lower than 85% you can use that value instead of 85%.

Example of manpower calculation

Situation : A customer wants a product P at the rate of 5000 units per day. This product P have three operations A, B & C, which requires man minutes 5, 8, 6 respectively. The company works for two shifts per day and working time per employee is 420 minutes. Normal efficiency of the operations of the company is 85%.

If you don’t know what is man minutes or man hour, read this article on man hour and come back.

Lets do some calculation…

Calculation:

So in this situation this company needs 134 peoples per shift for satisfying its customer demand (268 peoples per day).

We can also calculate manpower required directly from takt time.

Importance of capacity analysis in manpower planning

Please note that, if any equipment are using for these operations we need to do capacity analysis for the equipment before recruiting the peoples, otherwise if there is no enough equipment these manpower will be idle. I will explain the capacity analysis in another post. 

Manpower requirement calculation tool

I have prepared a tool for calculating the manpower required as described in this post. You only need to enter the values asked in the tool and click the ‘calculate manpower’ button. Then you can see the result. I am sharing its link below.

Click here for manpower requirement calculation tool

There is a different method to calculate manpower for office and clerical jobs. You may also refer that article.

Thank You for reading.

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Topics related to Manpower requirement calculation

Before you leave this page, try searching the below topics that is related to manpower requirement calculation. This will help you to explore more about this topic.

1. Manpower planning software
2. Workforce planning tools
3. Strategic workforce planning
4. Human capital management software
5. Talent acquisition software
6. Recruitment management system
7. Applicant tracking system
8. HR analytics software
9. Staffing agency software
10. Payroll software for staffing agencies

Manpower calculation for balanced assembly line with consistent demand

To know how to calculate manpower for balanced assembly line with consistent demand download the below excel file.

Every step is explained in detail with example.

Looking for Custom Manpower Calculation Templates?

We have provided two types of manpower calculation Excel templates, an online web tool, and an explanation of how to calculate manpower, in this article. If you need more customized Excel templates, our development team is ready to assist you.

These custom excel templates will help you in any of your manpower requirement calculation needs and manpower planning, for long term.

Contact us, and we will create an automated Excel template tailored to your needs. Please fill the form below and our team will get back to you to support you on custom manpower requirement calculation.

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