ZenithArea Manager

Free tool · Planning

Shift Capacity

How many people each process needs on each shift for the forecast volume, against the people planned, before the shift starts. Give every process its rate in units per productive hour, the shifts their breaks, the utilisation and the absence allowance, and the week its volume per day and shift. The tool works out the labour hours and the heads, the gap in heads and in hours, the capacity of the planned team and its bottleneck, and how to close a gap: overtime, agency, or qualified people from a process with spare hours.

1 · Processes and rates

Each process is counted in its own unit, at its rate in units per productive hour (UPH) from an engineered labour standard or a time study. When the forecast comes in another unit, the conversion turns it into the unit of the process, for example 2.4 lines per order.

ProcessCounted inRate (UPH)Forecast inConversionRemove

2 · Shifts
ShiftLength (h)Unpaid breaks (min)Paid breaks and briefing (min)Productive hours per personRemove

the share of the net time spent on measured work
sickness, short-notice leave and no-shows
what one person may add to a shift

Productive hours per person = (length − unpaid breaks − paid breaks and briefing) × utilisation. Heads = hours needed ÷ productive hours per person, rounded up; heads incl. absence = heads ÷ (1 − absence allowance), rounded up.

3 · Volume forecast

One row per day and shift, one volume per unit the processes are counted from.

No forecast yet. Add a day or paste the week from Excel, or .

Paste from Excel or CSV

One row per day and shift, columns in this order: . Tabs, semicolons or commas all work, and a header row is skipped. A day and shift already in the forecast gets the new volumes.

4 · Planned heads

Type the people planned per process, or only the total if they work across the processes.

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