The right skills for each task
Weighing, mixing and process checks require different qualifications. PLEXecute takes these into account when assigning staff. In our example, Alex and Sam can prepare batches and perform process checks. Kim is qualified only for process checks.
A qualified worker may already be assigned elsewhere. PLEXecute considers both the required skills and staff availability, helping you identify a bottleneck even when the team appears large enough.
Who can perform each task?
The overview shows the example team’s skills and working hours.
Alex
Batch preparation and process checks
08:00–16:00
Can prepare batches
Sam
Batch preparation and process checks
12:00–16:00
Can prepare batches
Kim
Process checks only
08:00–16:00
Can perform checks only
PLEXecute considers both when assigning staff.
How does a staff absence affect production?
When Alex is absent, Sam covers batch preparation. Because the replacement can start later, following tasks also move. Replanning in PLEXecute shows what the absence means for batch production.
Comparing the plans reveals that Sam can cover preparation, but one process check remains unscheduled. PLEXecute makes these gaps visible, helping your team decide where extra support or a revised delivery date is needed.
If both Alex and Sam are absent, the example team lacks the skills needed for batch preparation. The affected tasks remain unscheduled, making the need for action visible before the batch enters production.
The production plan before and after an absence
The baseline is above; the revised plan with Sam as cover is below. The highlighted check remains unscheduled.
Baseline plan
Alex handles both batches.
A100 · Batch preparation
Alex08:00–10:00A100 · Process check
Alex10:00–10:30B200 · Batch preparation
Alex10:30–12:00B200 · Process check
Alex12:00–12:30
- A100 · Batch preparation
- 08:00–10:00
- A100 · Process check
- 10:00–10:30
- B200 · Batch preparation
- 10:30–12:00
- B200 · Process check
- 12:00–12:30
Both batches are fully planned.
After Alex’s absence
Sam covers for Alex and starts later.
A100 · Batch preparation
08:00–12:00 · Waiting for qualified staff
Sam12:00–14:00A100 · Process check
Sam14:00–14:30B200 · Batch preparation
Sam14:30–16:00B200 · Process check
Not scheduled
- A100 · Batch preparation
- 12:00–14:00
- A100 · Process check
- 14:00–14:30
- B200 · Batch preparation
- 14:30–16:00
- B200 · Process check
- Not scheduled
The second batch’s process check remains unscheduled.
With replacement cover, the batches move and one check remains unscheduled.
Staffing needs can change during a batch
Starting a batch may need two skilled workers, while the remaining operation needs only one. PLEXecute can account for this changing demand, assigning extra support to the part of the process that needs it.
Two people at startup, one for the remaining operation
Height represents the number of people needed; width represents the duration of each segment.
- 2 skilled workers
- 30 min
- 1 skilled worker
- 90 min
Two skilled workers support startup; one continues with batch preparation.
Why factory-wide workforce planning needs software
For one batch, it may still be manageable to work out who can do each task and when. Across hundreds of batches, these decisions become connected: the same qualified people are needed in several places, shift windows limit their available time and some stages need extra support. When someone is absent, the effects on other batches and following tasks must also be checked.
PLEXecute helps manage these connections. It considers qualifications, availability and staffing demand in each segment when assigning people, alongside the production sequence. After a change, replanning shows which tasks can be scheduled with the remaining staff and which work remains unplanned. This gives your team a shared basis for evaluating cover, additional availability or revised dates.
How would you staff your next batch?
Plan qualified staffing through changing crew requirements and short-notice absences. Talk to us about bringing your workforce and production planning together with PLEXecute.