Workforce planning at USPS mail processing and distribution centers using stochastic optimization

Service organizations that operate outside the normal 8-hour day and face wide fluctuations in demand constantly struggle to optimize the size and composition of their workforce. Recent research has shown that improved personnel scheduling methods that take demand uncertainty into account can lead to significant reductions in labor costs. This paper addresses a staff planning and scheduling problem that arises at United States Postal Service (USPS) mail processing & distribution centers (P&DCs) and develops a two-stage stochastic integer program with recourse for the analysis. In the first stage, before the demand is known, the number of full-time and part-time employees is determined for the permanent workforce. In the second stage, the demand is revealed and workers are assigned to specific shifts during the week. When necessary, overtime and casual labor are used to satisfy demand. This paper consists of two parts: (1) the analysis of the demand distribution in light of historical data, and (2) the development and analysis of the stochastic integer programming model. Using weekly demand for a three-year period, we first investigate the possibility that there exists an end-of-month effect, i.e., the week at the end of month has larger volume than the other weeks. We show that the data fail to indicate that this is the case. In the computational phase of the work, three scenarios are considered: high, medium, and low demand. The stochastic optimization problem that results is a large-scale integer program that embodies the full set of contractual agreements and labor rules governing the design of the workforce at a P&DC. The usefulness of the model is evaluated by solving a This work was supported in part by the National Science Foundation under grants DMI-0218701 and DMI-0217927. J.F. Bard (!) · D.P. Morton Graduate Program in Operations Research, Department of Mechanical Engineering, The University of Texas, Austin, TX 78712-1063, USA e-mail: [email protected] D.P. Morton e-mail: [email protected] Y.M. Wang American Airline, AMR Corp Headquarter HDQ1, Fort Worth, Texas 76155, USA e-mail: [email protected] 52 Ann Oper Res (2007) 155: 51–78 series of instances constructed from data provided by the Dallas facility. The results indicate that significant savings are likely when the recourse problem is used to help structure the workforce.