# Industrial Engineering Research & Excel Modelling – Manufacturing Shift Systems and Four-Day Work Week

# Industrial Engineering Research & Excel Modelling – Manufacturing Shift Systems and Four-Day Work Week ## Project Overview I am looking for an experienced Industrial Engineer, Operations Research Specialist or Manufacturing Systems Analyst to assist with a research and modelling project examining the operational and economic implications of introducing different four-day working week models in manufacturing environments. The project focuses on understanding how alternative working-time arrangements affect production capacity, workforce requirements, staffing levels and labour costs. The research framework, proposed scenarios and general modelling approach have already been established. I am looking for someone with practical experience in manufacturing operations and quantitative analysis to help develop the model, validate the calculations and conduct the scenario analysis. ## Research Objective The main objective is to evaluate under which manufacturing conditions different four-day working week arrangements are operationally and economically feasible compared with conventional five-day working arrangements. The analysis will focus on two manufacturing environments: 1. **Two-shift manufacturing plant:** Two 8-hour shifts operating five days per week (80 operating hours). 2. **Continuous manufacturing plant:** Three-shift operation covering 24 hours per day, seven days per week (168 operating hours). ## Scenarios to Be Analysed The project will compare four working-time arrangements: - **Baseline:** Conventional five-day working week with 8-hour shifts. - **Scenario 1 – Compressed working week:** Four 10-hour working days, maintaining the same weekly contractual hours. - **Scenario 2 – Reduced working week:** Four 8-hour working days, reducing weekly contractual hours to 32. - **Scenario 3 – Rotating shift arrangement:** Four days on / four days off, using 12-hour shifts for continuous manufacturing operations. The scenarios should be evaluated against the baseline to understand their operational and economic implications. ## Required Modelling Work The main deliverable is a structured Excel-based scenario model. The model should include: **1. Workforce and Staffing Requirements** - Calculate the required workforce for each operating arrangement. - Estimate the number of employees and crews needed. - Account for contractual weekly working hours. - Incorporate absence allowances, including sickness, leave and training. - Assess staffing requirements for different shift structures. **2. Production Capacity Analysis** - Calculate available operating hours. - Estimate effective production capacity. - Incorporate machine availability and productivity assumptions. - Evaluate the impact of reduced working hours and longer shifts on production output. - Identify potential capacity shortfalls. **3. Labour Cost Analysis** - Calculate weekly labour costs under each scenario. - Evaluate the effect of additional staffing requirements. - Consider different compensation arrangements. - Calculate labour cost per unit of production. **4. Break-Even Analysis** - Determine the productivity improvement required for each alternative working arrangement to achieve the same labour cost per unit as the baseline. - Compare the required productivity improvements against published research findings. **5. Sensitivity Analysis** The model should allow different assumptions to be tested, including: - Employee absence rates. - Productivity changes. - Machine availability. - Production demand. - Fatigue-related productivity adjustments. - Labour cost and compensation assumptions. Low, medium and high scenarios should be considered where appropriate. **6. Operational Feasibility Assessment** Develop a comparison framework evaluating each arrangement according to: - Production capacity. - Workforce requirements. - Labour cost per unit. - Overtime requirements. - Legal and working-time constraints. - Fatigue and operational risks. ## Research and Literature The modelling work should be supported by relevant academic literature and credible industry sources covering: - Four-day working week models. - Compressed and reduced working schedules. - Manufacturing shift systems. - Workforce planning and capacity management. - Productivity under extended working hours. - Fatigue and occupational safety. - Labour costs and operational efficiency. Some preliminary academic references and research directions have already been identified. The purpose is not simply to produce calculations, but to ensure that the assumptions and model parameters are supported by credible research. ## Expected Deliverables 1. A functional and clearly structured Excel scenario model. 2. Documented formulas, assumptions and input parameters. 3. Comparative results for the two manufacturing environments. 4. Workforce, capacity and labour cost calculations. 5. Break-even productivity analysis. 6. Sensitivity analysis. 7. Relevant charts, tables and visual comparisons. 8. A short technical explanation of the modelling methodology and findings. The Excel model should be transparent, reusable and easy to modify by changing input assumptions. ## Ideal Freelancer Profile I am particularly interested in working with someone who has experience in: - Industrial Engineering. - Manufacturing systems and production planning. - Operations Research. - Workforce and shift scheduling. - Capacity planning. - Excel modelling and quantitative analysis. - Cost and productivity analysis. Experience with manufacturing simulation software or optimisation techniques would be beneficial, but the primary modelling environment will be Microsoft Excel. ## Important Project Considerations The research scope and scenarios are already defined. I am looking for someone who can understand the operational problem, help translate the research framework into a technically sound model, and produce reliable analytical results. The work should be developed progressively, with the modelling lo