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Solver to determine No. of workers required over a period of time

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    Solver to determine No. of workers required over a period of time

    Hello Everyone,

    I have never used Solver, but have a problem where I need to determine the number of workers required for a job scheduled over a period of +-3 months, with some constraints. Each day has a forecasted number of required workers for that day, with approximately 60% day shift and 40% night shift. Workers may only work 14 consecutive days of 12 hour shifts, after which they need to have a 7 day break. So the task need to determine the extra number of workers to employ, to be able to cover for the fatigue management constraint and complete the job.

    I am attaching a spreadsheet and would appreciate if someone can point me in the right direction or any assistance, as I have no idea where to start and how to structure the data to be able to run solver.

    Kind Regards

    Coenie
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    Forum Guru Kaper's Avatar
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    Re: Solver to determine No. of workers required over a period of time

    Sorry to say so, but I don't think the built-in solver will be OK, as there is a limit of ca. 200 variables, while here you have ca 90 days and may need well above 500 staff.

    Moreover some additional rules shall be described.
    For instance: what if a person works for 2 days and then have a free day. Shall he/she have 7 free (just after working 2 days) or can have 1 or 2 free and then work for instance 10 days and only then have 7 days free. And so on.
    I assume that it is possible to work some time on day shift and then (after 7 days break) on night one. But can it happen after 6.5 or 7.5 days (expect the second is required)?
    Best Regards,

    Kaper

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    Re: Solver to determine No. of workers required over a period of time

    Does this help or offer a way forward. I've added a couple of helper rows. It assumes that the project starts with all staff having 14 days available.
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    Re: Solver to determine No. of workers required over a period of time

    Solver may be enough if we assume that there are 21 fixed schedule types.
    Schedule A is 14/7, B is 13/7/1, C 12/7/2 and so on. In other words, each schedule after the first is shifted of 1 day, but has the same pattern for all 98 days.
    Our objective is finding how many workers must follow each schedule, and minimize the total workforce while having everyday at least the required workers.

    If this is enough for a start, check the Solver setup (and solution) in the file attached. You need at least 729 workers.

    HTH,

    Francesco
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    Re: Solver to determine No. of workers required over a period of time

    Thank You Hydraulics,

    Your solution is spot on and does exactly what I need. Just a question, how did you arrive at the number of workers in A3:A23 or is this where you manually plan how many workers you want to add on a particular schedule?

    Really appreciate the assistance.

    Kind Regards

    Coenie
    Last edited by Coenieh; 06-12-2021 at 12:11 AM.

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    Re: Solver to determine No. of workers required over a period of time

    Thank you Richard,

    I'll work through your solution and see if I can use it to finalize the forecast model

    Kind Regards

    Coenie

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    Re: Solver to determine No. of workers required over a period of time

    Quote Originally Posted by Coenieh View Post
    Just a question, how did you arrive at the number of workers in A3:A23 or is this where you manually plan how many workers you want to add on a particular schedule?
    Cells A3:A23 are the variables, Solver finds the values for us.

    This is really a minimum setup: one constraint linked to covering the demand in each day, and one to force the variables to integers. Moreover, it is based on a very strong assumption about scheduling.

    It's not clear to me if this is a real world problem: I would expect both more constraints (for instance, we cannot have too many idle workers) and flexibility (scheduling must respect at least a 14w/7b cycle, but a worker may follow a 5w/12b/9w), and some economic reasoning (minimize costs).
    As Kaper wrote, Solver (and even OpenSolver, a free and much powerful add-in) will not be enough, in general, to solve exactly the problem.

    HTH,

    Francesco

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    Re: Solver to determine No. of workers required over a period of time

    Hi Hydraulics,

    Thanks for the response. The workers are all part time workers and are only contracted on a short-term basis. This is in plant maintenance shut environment, where I need to plan for the quarter ahead. We plan according to the maintenance tasks required.
    In this scenario, we require the number of workers per day, as per the sheet. However, workers are only allowed to work 14 days (12 hour shifts day or night)
    after which they are required to rest for 7 days. So the schedule will only be 14/7. I need to determine the total number of workers, required to be contracted over the period to cover the period when the 1st team are resting.

    Hope this explanation makes more sense

    Kind Regards
    Coenie.

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