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["THT Staffing Audit Worksheet"]
[]
["Section 1: Line Information"]
["Parameter","Your Value","Units","Notes"]
["Number of manual THT stations",null,"stations","Count all insertion positions"]
["Operators per shift",null,"operators","People working at these stations"]
["Number of shifts per day",null,"shifts","1, 2, or 3"]
["Total operators (all shifts)",{"$f":"IF(B6*B7=0,\"\",B6*B7)","v":null},"operators","Auto-calculated"]
[]
["Section 2: Productivity"]
["Parameter","Your Value","Units","Notes"]
["Average CPH per operator",null,"CPH","Typical: 200-600 for THT"]
["PCBs produced per day",null,"boards","Average daily output"]
["THT components per PCB",null,"components","Inserted manually"]
[]
["Section 3: Rework"]
["Parameter","Your Value","Units","Notes"]
["First-pass rework rate",null,"%","Typical: 3-8% for manual THT"]
["Rework cost per board",null,"$","Include labor + downtime"]
["Annual rework cost",{"$f":"(B9*B10*B12/100)*(250/7)*B13","v":null},"$","Auto-calculated (250 work days)"]
[]
["Section 4: Hidden Costs"]
["Parameter","Your Value","Units","Notes"]
["Supervisors assigned to THT area",null,"people","Line leads + shift supervisors"]
["Supervisor annual cost per person",null,"$","Fully loaded salary"]
["Operator annual turnover rate",null,"%","Typical: 30-50% in PRD EMS"]
["Training cost per new hire",null,"$","Weeks of reduced productivity"]
["Average trained operators per station",null,null,"How many are fully trained?"]
[]
["Section 5: Cost Summary"]
["Cost Category","Annual Value","% of Total","Notes"]
["Direct labor cost",{"$f":"B5*250*8*20","v":null},"$","Estimate: operators x days x hrs x base rate"]
["Rework cost",{"$f":"B14","v":null},"$","From Section 3"]
["Supervisory cost",{"$f":"B18*B19","v":null},"$","From Section 4"]
["Total annual THT cost",{"$f":"SUM(B31:B33)","v":null},"$","Sum of all costs"]
[]
["Section 6: Auto Insertion Comparison"]
["Parameter","Value","Units","Notes"]
["Auto insertion CPH (e.g. S4000)","20,000","CPH","Typical axial machine"]
["Equivalent machines needed",{"$f":"ROUNDUP(B10/B38,0)","v":null},"machines","Based on current throughput"]
["Operators needed (1 per 4 machines)",{"$f":"ROUNDUP(B39/4,0)","v":null},"operators","Auto-calculated"]
["Estimated annual savings",{"$f":"B34*0.4","v":null},"$","~40% cost reduction typical"]