Returns FC — Capacity Flow Balancer

🔵 CLEAN DECANT — UPSTREAM SORTATION

Line	Headcount	Hourly Output
Line 1		340
Line 2		340
TOTAL	8	680

Blended Rate: 85.0 UPH/person

🟢 SPEC 05 GRADERS — DOWNSTREAM

Area	Headcount	Rate (UPH)	Hourly Capacity
Spec 05 Graders			360
TOTAL	8		360

Spec 05 processes all units flowing from Clean Decant

🟣 FLOW BALANCE — CLEAN DECANT vs SPEC 05 GRADERS

CD Output (units/hr)

680

Spec 05 Capacity (units/hr)

360

Surplus / Deficit

+320

Combined HC

Spec 05

CLEAN DECANT OVERPRODUCING

🟠 INVENTORY — CAGE TRACKER

1 Cage = 12 Totes × 10 Units = 120 Units/Cage

Drop Zone	# Cages	Units	% of Total
Line 1 RIV Drop Zone		1,200	55.6%
Line 4/5 Inject Drop Zone		960	44.4%
TOTAL INVENTORY	18	2,160

Target Cages Remaining (EOS)		360 units
UNITS TO PROCESS	15 cages	1,800 units

🔴 SHIFT TIME CALCULATOR

Shift Start	7:30 AM	Shift End	6:00 PM
Break 1	11:00 – 11:30 AM	Break 2	3:00 – 3:30 PM
Total Shift	10.5 hrs	Total Productive	9.5 hrs

CURRENT TIME: --:-- -- CT MANUAL OVERRIDE

Auto-updates every minute (Central Time — America/Chicago)

Time to Shift End

8.00 hrs

Remaining Breaks

1.00 hrs

Productive Hours Left

7.00 hrs

📈 HEADCOUNT ADJUSTMENT RECOMMENDATIONS

Based on remaining inventory, productive hours left, and current staffing — recommendations to clear target units and maintain flow balance

Units to Process

1,800

Productive Hrs Left

7.00

Required Throughput

258 u/hr

Current CD Output

680

Current Spec 05

360

Area	Current HC	Rate	Current Output	Rec. HC	Rec. Output	HC Change	Action
Clean Decant	8	85.0	680	4	340	-4	REMOVE 4 HC
Spec 05 Graders	8	45	360	8	360	0	NO CHANGE

✅ PROJECTED SHIFT OUTCOME (If Recommendations Applied)

Rec. CD Output (u/hr)

340

Rec. Spec 05 Cap (u/hr)

360

Flow Balance (u/hr delta)

-20

Projected Units Produced

2,380

Units to Process Target

1,800

Surplus / Shortfall

+580

🕑 HOURLY FLOW PROJECTION TABLE (Next 10 Hours from Current Time)

Hour #	Clock Time	Status	CD Cumulative	Spec 05 Cumulative	Cumul. Delta	Cages Remaining	Progress