Constraint
The crew is 1.84 FTE short on an average day. The operation is already above 100% capacity utilisation.
Key numbers
- Required FTE
- 7.84
- Available capacity
- 765
- Capacity utilisation
- 130.7%
- Additional FTE
- 1.84
- +20% volume FTE
- 9.41
Assumptions
- Process time includes walk, pick and confirm for the average case.
- Breaks are already outside the 7.5 hours, or set to zero because hours are net.
- No batching or zone-pick interaction is modelled here.
Method
- Required FTE = (volume × process time) ÷ (net minutes × utilisation).
- Available volume = current FTE × productive minutes ÷ process time.
- Show the +20% case before the meeting.
Proposed solution
Staff 8 pickers (round 7.84 up) or reduce pick time toward 2.3 minutes. Overtime can cover a short week; it is not the roster.
Limitation
If the 3.00 minutes already includes an 85% allowance, do not apply utilisation again.