The “Factory Load Monitor” tool is a web-based application designed to help monitor the load on a factory in terms of the number of operators required to produce a certain number of components. It takes input values such as the number of components to produce, the number of days available to produce them, cycle times for each department (Assembly, Machining, Painting, Electrical, Testing, and Shipping), operator absenteeism rate, efficiency, indirect hours per day, and the number of operators available for each department.

For example, let’s say a factory is tasked with producing 10,000 components in a month. The factory has 20 working days in the month, and each working day is 8 hours long. The factory has six departments: Assembly, Machining, Painting, Electrical, Testing, and Shipping.

To use the tool, the user would input the following values:

• Components: 10,000
• Days Available: 20
• Assembly Cycle Time: 20 minutes
• Machining Cycle Time: 30 minutes
• Painting Cycle Time: 40 minutes
• Electrical Cycle Time: 25 minutes
• Testing Cycle Time: 35 minutes
• Shipping Cycle Time: 15 minutes
• Absenteeism Rate: 5% (assuming 5% of operators are absent on any given day)
• Efficiency: 90% (assuming the factory operates at 90% efficiency)
• Indirect Hours: 1 hour (assuming each operator spends 1 hour per day on indirect tasks)
• Assembly Operators: 10
• Machining Operators: 8
• Painting Operators: 6
• Electrical Operators: 12
• Testing Operators: 4
• Shipping Operators: 5

Based on these inputs, the tool calculates the number of operators required for each department to produce 10,000 components in 20 days. For example, the tool would calculate that the Assembly department requires 7 operators, the Machining department requires 9 operators, the Painting department requires 10 operators, and so on.

The tool then displays these results in a table, including the required operators for each department, the operators available for each department, and the difference between the required and available operators for each department. The tool also plots the required and available operators for each department in a bar chart for visual representation.

The user can then use this information to adjust staffing levels in each department as needed to ensure that the factory can meet its production goals efficiently. The “Factory Load Monitor” tool can help factories manage their workload more efficiently by providing insight into the number of operators required for each department and identifying any potential staffing shortages.