Hi Kevin,
Are you talking about your experience in Singapore or India ?
That apart, generally, in the circumstances and as many suggestions posed here there are more than one solution is available to you. Prior to go for a single decision, you should have done your work study by Industrial Engg. concepts. You haven't mentioned whether your plant runs single shift or multiple shift, rather you only talked about 'daily basis'. I'm looking at it the possibility of running the machines in 3 shifts of 8 hrs shift (as what we have in India) if this is feasible.
Secondly, by now you would have kept your past record on the frequency of leave of absence and resultant 'idle time' of machinery. This data should tell you clearly the pattern of staff who go on leave on daily basis and how many machines idling due to absence. I'm sure if such a data is available to you, a solution also will be ready. The available solution are only as known by every body, they could be listed thus -
1) Create back up strength, the Nos. required will be driven by the past data;
2) If you are running more than 3 shifts this task could be easily accomplished;
3) Resort to OT or Compensatory off to some of the existing/willing 100 staff who could come into their shoes;
4) Outsource the shortage arising due to leave either on piece rate or time rate computed on 'machine hour or man hour rates'. In doing so you should have made the 'cost benefit analysis' to assist you in decision making;
5) Plan routine or break down or preventive maintenance of all machines, on daily basis, by rotation so that down time due to absence is not felt.

From India, Bangalore
Vaughn Ellers
Hello! I believe that in order to optimize the production process, it is necessary to hold meetings among the plant workers and make presentations on the topic of labor optimization and interaction between employees. Here you can choose a projector and make a mini projector comparison. This equipment will allow you to make quick, affordable and high-quality presentations.
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From India, undefined

As per factories Act you have to give 1 leave for 20 working days.
Now out of 365 days, 52 are weekly offs so now total available days for each worker are 313 days considering no leaves taken. Now leaves will be 15.65 ( 16 rounded).
16 leaves per year means 1.33 (1.5 rounded) per month. So for 100 workers it is 150 days leave out of 31300 available work days.
Now per day leaves are 0.05 per worker means 5 workers would be on leave for each day. So considering operations in single shift you would require 5 additional workers each day.
Now if additional absenteeism happens due to sickness may be 2 employees each day. Means 7 employees required so you need to hire additional 7 employees. i.e. minimum 107 employees required. Note: this is not for 3 shift operations. if in 3 shifts the logic will be different.

From India, Mumbai

Well you need to do proper planning first of all:

1)Identify the minimum amount of employees that are a must need for daily operations.
2)Keep a few number of additional trainee employees.
3)Divide the task in shifts.
4)Keep a backup of outsources for specific situations.
5)Track the leaves of employees using an effective mechanism so to avoid unnecessary leaves
6) Ensure health and safety within work place to avoid large percentage of sick leaves.
I hope this helps. GOODLUCK.

From Pakistan, Islamabad

you need study about "TIME AND MOTION STUDY" to analyse machine capacity and manpower planing.
and also you need to analyse last 6 months about Absent & Leave.
take average persons absent & Leave, that average manpower to extra manpower.

From India, Bangalore

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