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.
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.