Lay out your operation’s schedule and compare the common patterns: how many crews and people, how many hours each works per week, whether every shift is covered and what it costs per month.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
People needed including reserve (bars) and average hours per person per week (line), with 8- or 12-hour shifts per pattern. The dashed line is the weekly limit entered.
Base wage, night premium and hours above the weekly limit, plus payroll burden, for each schedule’s headcount.
W = crew working. The last row compares crews on duty with the shifts needed that day.
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It lays out your shift schedule and works out how many crews and people you need, how many hours each person works per week and month, whether every shift is covered and what the schedule costs. It also compares the common patterns (2-2-3, DuPont, continental, 12 on 36 off, 5x2, 6x1, 4x2 and 6 on 2 off) for the same operation.
No. Labor laws and collective bargaining agreements in each country must be evaluated and taken into account; this is the user’s responsibility. The calculator does not check legal limits: the weekly limit field only compares hours against the number you enter.
Crews = shifts per day × (operating days ÷ 7) × (cycle days ÷ days worked). In the example, two 12-hour shifts, 7 days a week, on a 2-2-3: 2 × 1 × 14 ÷ 7 = 4 crews. With 5 positions per shift that is 20 people, and with a 10% reserve, 22.
With 12-hour shifts and a 30-minute unpaid break, each person averages 40.3 hours a week, alternating 34.5 and 46 hours, so the 46-hour weeks carry 6 hours over 40. At $4,000 a month base, 173.3 hours, a 10% night differential, 50% overtime premium and 35% burden, payroll is about $136,000 a month.
Because each shift covers 12 hours: two shifts a day and four crews keep the plant running around the clock, each crew working half the days. Eight-hour continental rotations also use 4 crews but each person works more days with shorter shifts. The chart shows people and weekly hours for each pattern side by side.
It is extra staff to cover vacation, absences, leave and training without empty positions. It depends on your PTO policy and absenteeism; use the manpower staffing calculator linked at the bottom of the page to work it out from your own data.
Crews are assumed to rotate through all shifts, so night hours and shift length are averages. Overtime is checked per calendar week of the cycle against the limit you enter; state daily overtime rules, holiday pay and union terms are not included. Validate the schedule with HR, legal counsel and the union before rolling it out.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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