Departemen Teknik Industri FTI-ITB

TI-3122
Perencanaan dan Pengendalian Produksi

Perencanaan Tenaga Kerja

Laboratorium Sistem Produksi

www.lspitb.org
©2003

Departemen Teknik Industri FTI-ITB

Hasil Pembelajaran
• Umum
ƒ Mahasiswa mampu menerapkan model matematik,
heuristik dan teknik statistik untuk menganalisis dan
merancang suatu sistem perencanaan dan pengendalian
produksi

• Khusus
ƒ Mampu menghitung kebutuhan tenaga kerja

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Departemen Teknik Industri FTI-ITB

INTRODUCTION
(Production Planning System)
Aggregate Planning

Master Production Schedule

Material Requirements Planning

Planned Order Release/Scheduling

Production scheduling staffing facility with people

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Departemen Teknik Industri FTI-ITB

INTRODUCTION
(Characteristics)
• Characteristics:
ƒ Demand tends to fluctuate widely in the short term and
to occur seven days a week
ƒ Human effort cannot be inventoried
ƒ Customer convenience is critical

• Steps to solve the problem:

ƒ Identify the services to be provided
ƒ Determine the average time required for each service
ƒ Forecast the demand for each service over the seven
day period and for the staffs
ƒ Smooth out the staffing needs

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Departemen Teknik Industri FTI-ITB

INTRODUCTION
(Definition)
• Demand: the number of people needed during some
periods to provide a predefined level of service. A weekly
demand forecast is the number of people to be employed
during each day of the week

• Shift:
ƒ (1) the time of a day when a person begins work and takes a
rest and breaks during the day. Example: Shift 5 starts at
08:00 with 15 minutes off at 10:00 and 14:00, and lunch from
12:15 to 12:45
ƒ (2) the set of days during a given week when a person will be
expected at work. Example: Shift 5 is Monday through Friday,
with Saturday and Sunday off

• Schedule: the set of shifts that satisfies the demand criteria

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Departemen Teknik Industri FTI-ITB

SHIFT SCHEDULING
• Objective: to provide an adequate number of people at
minimum labor cost

• A total of 28 people-days
• Since each individual works 5 days, it requires 6 shifts (6
people)
• Figure 1 shows a very simple daily demand forecast and
shift schedule
• The solution contains overstaffing on Tuesday and Friday. It
contains only 2 Saturday/Monday off shifts but everyone at
least has consecutive days off
• The solution is optimal in that it requires six people (the
minimum feasible)

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Departemen Teknik Industri FTI-ITB

Sun Mo Tue We Thu Fri Sat

n d #1
Shift

Shift #2

Shift #3

Shift #4

Shift #5

Shift #6
Sum
Staff 2 4 5 5 5 5 4 30
Demand 2 4 4 5 5 4 4 28
Overstaff 0 0 1 0 0 1 0 2

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Departemen Teknik Industri FTI-ITB

ALGORITHMS
Tibrewala, Philippe, and Browne

• Step 1: Working from the largest manpower-

need day to the second largest and so forth, do
the following. Place all days with the same
manpower need on the schedule until a unique
two-consecutive-days off period appears. If a tie
exists, go to Step 2.
• Step 2: If two identical two-days-off periods
occur, select the pair with the smallest
requirements on adjacent days. If the tie cannot
be broken, go to Step 3.
• Step 3: Select the most reasonable pair; for
example, the one that has a Saturday/Sunday off
or the first pair in the week
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Departemen Teknik Industri FTI-ITB

Sun Mon Tue Wed Thu Fri Sat

4 8 7 7 7 7 6 Init.dem

0 -1 -1 -1 -1 -1 0 #1

4 7 6 6 6 6 6

0 -1 -1 -1 -1 -1 0 #2

4 6 5 5 5 5 6

-1 -1 0 0 -1 -1 -1 #3

3 5 5 5 4 4 5

-1 -1 -1 -1 0 0 -1 #4

2 4 4 4 4 4 4

0 -1 -1 -1 -1 -1 0 #5

2 3 3 3 3 3 4

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Departemen Teknik Industri FTI-ITB

2 3 3 3 3 3 4

0 0 -1 -1 -1 -1 -1 #6

2 3 2 2 2 2 3

-1 -1 0 0 -1 -1 -1 #7

1 2 2 2 1 1 2

-1 -1 -1 -1 0 0 -1 #8

0 1 1 1 1 1 1

0 -1 -1 -1 -1 -1 0 #9

0 0 0 0 0 0 1

0 0 -1 -1 -1 -1 -1 #10

0 0 -1 -1 -1 -1 0

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Departemen Teknik Industri FTI-ITB

Demand Total: 46

Requirement: 45/6 = 9.2 ~ 10 people, 4 overstaff

Solution 4 shifts with Saturday/Sunday off

2 shifts with Sunday/Monday off

2 shifts with Tuesday/Wednesday off

2 shifts with Thursday/Friday off

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Departemen Teknik Industri FTI-ITB

ALGORITHMS
Monroe

• Step 1. For each day of the week, calculate the

regular days off (RDOs) by subtracting the daily
staff need from the chosen staff size. The
summed staff need must be an even multiple of 5
if five-day work weeks are to be scheduled. If
this is not the case, add to the staff needs of one
or more days until a multiple of five is reached.

• Step2. Beginning with the first two days of the

week, establish pairs of RDOs until the first pair
is repeated second time.

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ALGORITHMS
Monroe
• Step 3. For a first trial at scheduling pairs of RDO, assign
approximately half of the second day’s RDO to the first pair
of days off. Subtracting this assignment from the second
day’s RDO, assign the reminder to the second pair of days
off. Continue this procedure until all pairs have assignments.
If the first and second occurrences of the first pair are
equal, stop; otherwise go to Step 4.

• Step 4. Calculate the average of the assignment to the first

and second occurrences of the first pair of days off. Use this
as the second trial assignment for the first pair. Using this
procedure in Step 3, reassign all pairs of days off.

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE
(Example)
• Demand: 46 people-days

• To make the demand a multiple of 5, there are

two alternatives: 46 45 or 46 50

• If the chosen alternative is to adjust the demand

to be 50, Minimum required staff : 50/5=10,
meaning that there are 4 extra (dummy) demand
allocated to Tuesday, Wednesday, Thursday and
Friday

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE
(Example)
Sun Mo Tue We Thu Fri Sat

Initial demand 4 8 7 7 7 7 6

Adjusted 4 8 8 8 8 8 6

Minimum staff 10 10 10 10 10 10 10

Forecasted demand 4 8 8 8 8 8 6

Reg.day off (RDO) 6 2 2 2 2 2 4

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Departemen Teknik Industri FTI-ITB

ALGORITHMS MONROE
(Example)
Su Mo Tu We Th Fr Sa Su Mon

RDOs 6 2 2 2 2 2 4 (6) (2)

Dayoff pairs S/ M/ T/ W/ T/ F/ S/ S/M

M T W T F S S
First trial 1 1 1 1 1 1 3 (3)
Second trial 2 0 2 0 2 0 4 (2)

Solution: 2 S/M off schedules

2 T/W off schedules
2 T/F off schedules
4 S/S off schedules

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Departemen Teknik Industri FTI-ITB

Mabert and Raedels’s Method

• Part time worker need
Sun Mo Tue We Thu Fri Sat

Total need 0 11 6 8 6 10 0

Full time 0 5 5 5 5 5 0

Part time 0 6 1 3 1 5 0

Worker ID number: 1, 2, 3, 4, 5 and 6

The lower ID number the greater seniority
Seniority people desire to work maximum hour

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Departemen Teknik Industri FTI-ITB

Mabert and Raedels’s Method

The resulting schedule

Monday 1, 2, 3, 4, 5, 6

Tuesday 1

Wednesday 2, 3, 4,

Thursday 5

Friday 6, 1, 2, 3, 4

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Departemen Teknik Industri FTI-ITB

Linear Programming Model

(Monroe’s Algorithm)
• Definitions (Rothstein)
x1= number of Sun/Mon RDO pairs; b1= required RDO for Mon
x2= number of Mon/Tue RDO pairs; b2= required RDO for Tue
x3= number of Tue/Wed RDO pairs; b3= required RDO for Wed
x4= number of Wed/Thu RDO pairs; b4= required RDO for Thu
x5= number of Thu/Fri RDO pairs; b5= required RDO for Fri
x6= number of Fri/Sat RDO pairs; b6= required RDO for Sat
x7= number of Sat/Sun RDO pairs; b7= required RDO for Sun
u1= number of Mon in non consecutive RDOs
u2= number of Tue in non consecutive RDOs
u3= number of Wed in non consecutive RDOs
u4= number of Thu in non consecutive RDOs
u5= number of Fri in non consecutive RDOs
u6= number of Sat in non consecutive RDOs
u7= number of Sun in non consecutive RDOs
d = number of workers who will be assigned non consecutive RDOs

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