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han-nam
Hello

Am kindly seeking for technical guidance on the following topics
How to calculate backlog to establish overload, normal load and under load in a manufacturing company to facilitate manpower planning

From Israel
raghunath_bv
162

Hi Nam Ham,

Calculating backlog and using it to establish workload levels in a manufacturing company is an important aspect of manpower planning. Here's a step-by-step guide on how to do it:

Define Terminology:
Backlog: This refers to the accumulation of unfinished work or orders that have not been completed within the expected time frame.
Gather Data:

Collect historical data on production orders, including order quantities, due dates, and actual completion dates.
Calculate Backlog:

To calculate the backlog, subtract the actual completion date from the due date for each production order. This will give you the delay for each order.
Example:

Order 1: Due Date - Actual Completion Date = Backlog Days
Order 2: Due Date - Actual Completion Date = Backlog Days

Categorize Backlog:
Based on the backlog days, categorize orders into different groups such as:

Orders with a significant backlog (e.g., more than a certain number of days).

Orders with a moderate backlog.

Under Load: Orders with little or no backlog.

Set Thresholds:
Define specific criteria or thresholds that determine what constitutes overload, normal load, and under load. These thresholds will be based on your company's specific circumstances and capabilities.

Analyze Trends:
Look for patterns in backlog data over time. This will help you identify seasonal variations or recurring issues that may affect workload.
Consider Capacity:

Take into account the production capacity of your manufacturing facility. This includes factors like machine availability, workforce capabilities, and other resources.

Based on the categorization and capacity considerations, adjust the allocation of resources (i.e., manpower) to address the backlog. For example, if there is an overload, you may need to allocate additional manpower or consider overtime.
Monitor Progress:

Continuously monitor the progress of backlog reduction. Adjust manpower allocation as needed to maintain a balanced workload.
Regular Review and Adjustment:

Periodically review your backlog data and workload allocation. Adjust your thresholds and strategies based on performance and changing business conditions.
Utilize Software and Tools:
Consider using manufacturing software or ERP systems that have features for tracking and managing backlog. These tools can automate the process and provide insights into workload distribution.

Effective manpower planning is a dynamic process that requires regular evaluation and adjustment based on the evolving needs of your manufacturing company. It's important to have a clear understanding of your company's specific production processes and capacity constraints to make accurate assessments.

Thanks

From India, Bangalore
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