Constraint
The headline 7.84 FTE understates the roster. After absence and indirect labour the operation needs about 9.8 FTE.
Key numbers
- Direct unadjusted
- 7.84
- Direct with absence
- 8.53
- Indirect FTE
- 1.28
- Total FTE
- 9.80
- Direct shortfall
- 2.53
- Weekly hours short
- 94.7
- OT hours available
- 30.0
- OT can cover?
- No
- Process time that closes the unit gap
- 2.29 min
Assumptions
- Unadjusted direct FTE uses 85% planned utilisation.
- Absence 8% covers holiday, sick and training.
- Indirect 15% covers team leaders and process support.
- Five overtime hours per person per week are available, not planned.
Method
- Direct unadjusted = volume × time ÷ productive minutes.
- Direct with absence = unadjusted ÷ (1 − absence).
- Total = direct with absence × (1 + indirect).
- Compare paid overtime hours available with weekly paid hours short.
Proposed solution
Roster 9–10 people, or take process time down and keep a smaller crew. Use overtime only as recovery. Present the three levers separately.
Limitation
If team leaders already pick, the indirect allowance is double-counting.