Workforce optimisation for pharma plants: a weekly shift roster and a 12-month headcount plan, built from the plant's existing ERP, HR and training data.
Two parts of one system, running in production at a global pharma's tablet manufacturing and packaging plant.
Supervisors built the weekly roster by hand across manufacturing rooms, packaging lines and three overlapping shifts, matching each worker's training to each room and keeping a technical lead on every line. Hiring needs surfaced late.
We brought the plant's ERP demand, HR, training and shift data together, built a roster engine that respects every certification and line rule and learns from past output to choose between equally qualified workers, and added a 12-month headcount projection by skill level.
The approach can be adapted to other shift-based plants.
