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.
Please note there are two types of Manpower Direct Labour (DL) and Indirect Labour (IDL). In this article we are only dealing with DL.
What you will get from this article:
- Watch Training Video at the end of this article.
- Download Manpower calculation excel templates.
- Formula to calculate manpower.
- Manpower calculation explained with examples.
- An opportunity to use our online manpower calculation tool.
- Get in touch with our Manpower calculation experts.
- Manpower Availability Factor (MAF)
Manpower calculation using Takt Time - Excel Template
This Excel-based manpower calculation template helps you calculate standard manpower requirements based on takt time. Ideal for Industrial Engineers and Production Planners.
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Manpower calculation Standard Template - Excel Template
This Excel-based manpower calculation template helps you calculate standard manpower requirements based on cycle time of multiple operations and demand. Ideal for Industrial Engineers and Production Planners.
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Manpower Calculation of Balanced Assembly Line Template
This Excel-based manpower calculation template helps you calculate standard manpower requirements based on cycle time of multiple operations and demand. The specialty of this template is that it can calculate the manpower required for a balanced assembly line in a high-volume production environment. Ideal for Industrial Engineers and Production Planners.
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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. Standard times are arrived using Time and Motion Study technique.
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 here 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.
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very effective calculation to run a industrial process
Undoubtedly the great calculation tool ,solves complex calculations and saves time.
Great! Complex calculation can be done in simple way. Kudos to the aurhor!
Great information
Dear Friend
We are automotive parts manufacturing company, having 100+ numbers of cnc machines working under one roof. I am in need of manpower ratio to machine for effective maintenance execution
Hi.. Makarand,
We can definitely help you in this. First we need to list down the maintenance activities and its time. From that we can arrive the manpower required for maintenance activity.
lets connect.
Please call or message on number +91 8089036992.
Hi… Makarand,
We are still waiting for your response.
Hello Mr. Melvin,
I need your support in the below.
I have total Cycle times for different projects. Lets say each projects has different products with different cycle times and I would like to know what exactly the manpower required to complete all these projects. Atleast need an estimated manpower requirement
Hi
Use the following tool
https://knowindustrialengineering.com/product-mix-manpower-calculator/
Mr. Melvin
Could you please give me an idea to calculate ballast tank mud/slurry removal, Surface preparation & paint touch-up
No of Tanks. :10
Total area : 3000m2
Paint touch-up. : 6000m2
(two times application)
Duration. : 10 days
Mr Melvin
Can you you reply me please
For this we need more data….
Time required for removing specific amount of slurry/mud by specific no of persons.
Amount of slurry or mud in tank
Time required for painting etc.
If you are able to provide these data… we can definitely help.
Thank you Mr. Melvin for you sent my question supported by using example for man power calculation of preventive maintenance with varying frequency. I hope next time we will meet by another thoughts regarding man power calculation. bye
Hi Erama… How are you. Its been a long time. Do we have a new topic to discuss regarding manpower calculation?
Hi Mr.Melvin, first I would like to thank you for you send a response for my question on man power calculation for preventive maintenance. I read it and it is help full to me, now let me add another related question on it. That is ” If I want to implement a preventive maintenance in different machineries in any industry in daily, weekly, monthly, quarter and yearly base, how I calculate or estimate the number of man power to perform effectively, for example, some machines are checked and lubricated daily, some are weekly, quarterly yearly according to the criticality of the machine and recommended by the manufacturer.
Good Question. I will give answer in another article shortly.
Hi Erama,
We have published the article. https://knowindustrialengineering.com/how-to-calculate-manpower-for-preventive-maintenance-with-varying-checklist-frequency/
Please have a look
I need your help to estimate/implement the man hour for machine lubrications and preventing maintenance work in any industry
We have published an article, please have a look
https://knowindustrialengineering.com/how-to-calculate-manpower-for-preventive-maintenance/