Demand Planner is a feature within Kaizen Copilot that bridges the gap between your production time studies and real-world staffing requirements — giving plant managers and industrial engineers precise, data-driven headcount planning across every shift, station, and product on their line.
What’s Covered in This Demo:
– Creating a Demand Planner line from the Line Balancing homepage
– Configuring a planning timeline of up to 12 months
– Adding products with utilisation, yield, and batch size inputs
– Entering planned production volumes by product and month
– Defining up to 15 shifts with gross time, scheduled breaks, and production days
– Assigning shifts to products — with per-period flexibility
– Importing data directly from an existing station design study
– Mapping precedence between steps and products to stations
– Entering yield percentages per product-station combination
– Reviewing staffing output per shift, per station, and per product
– Viewing a full line-level summary with tact time, cycle time, labour utilisation, and total headcount
How Plant Managers and Industrial Engineers Use It
Teams responsible for production capacity can use Demand Planner to:
– Replace manual spreadsheet-based headcount calculations
– Account for holidays, weekend-only shifts, and variable production calendars
– Reuse existing station design studies without re-entering data
– See how staffing needs shift month over month across the planning horizon
– Produce a complete line summary with a single click
Why It Matters
Demand Planner helps manufacturers:
– Eliminate guesswork in staffing and capacity decisions
– Align headcount directly to real production volumes and tact time
– Plan confidently across multiple products, shifts, and time horizons
– Connect time study data to operational outcomes without manual effort
Use Demand Planner to make your capacity planning as precise as your production data.
Learn more at:
https://retrocausal.ai/kaizen/
