# SAP QM Inspection Workload and FTE Calculator

> Source: https://netray.co/tools/sap-qm-inspection-workload-fte-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Turn inspection lot volume, characteristics per lot and skip-lot rate into monthly inspection hours, staff needed and cost.

## Category

sap

## Erp

SAP QM

## Audience

- Quality manager
- SAP QM consultant
- Plant manager

## Tool

**Kind:** calculator

**Currency:** $

**Inputs:**

#### Inspection lots per month

**Key:** lots

**Type:** number

**Default:** 900

**Min:** 0

**Step:** 50

**Unit:** lots

**Help:** Count of lots created per month, for example from QA32.

#### Characteristics per lot

**Key:** chars

**Type:** number

**Default:** 12

**Min:** 0

**Step:** 1

**Unit:** chars

**Help:** Average inspected characteristics, counting sample units if each is measured.

#### Minutes per characteristic

**Key:** min_char

**Type:** number

**Default:** 1.5

**Min:** 0

**Step:** 0.1

**Unit:** min

**Help:** Measurement time including reading and recording.

#### Setup and sample draw per lot

**Key:** setup

**Type:** number

**Default:** 6

**Min:** 0

**Step:** 1

**Unit:** min

#### Results review and usage decision per lot

**Key:** ud

**Type:** number

**Default:** 4

**Min:** 0

**Step:** 1

**Unit:** min

#### Share of lots skipped by dynamic modification

**Key:** skip

**Type:** slider

**Default:** 20

**Min:** 0

**Max:** 90

**Step:** 5

**Unit:** %

**Help:** Lots released with no inspection under skip rules. Skipped lots still need a usage decision in most setups.

#### Productive hours per inspector per month

**Key:** hours_fte

**Type:** number

**Default:** 130

**Min:** 40

**Step:** 5

**Unit:** hours

#### Loaded cost per inspector hour

**Key:** rate

**Type:** number

**Default:** 24

**Min:** 0

**Step:** 1

**Unit:** $/h

**Outputs:**

#### Minutes per inspected lot

**Key:** min_lot

**Expr:** chars * min_char + setup + ud

**Format:** decimal

#### Lots inspected per month

**Key:** inspected

**Expr:** lots * (1 - skip / 100)

**Format:** integer

#### Inspection hours per month

**Key:** hours

**Expr:** inspected * min_lot / 60 + (lots - inspected) * ud / 60

**Format:** number

**Primary:** true

**Description:** Skipped lots still carry the review and decision time.

#### Inspectors needed (FTE)

**Key:** fte

**Expr:** hours / hours_fte

**Format:** decimal

**Primary:** true

#### Monthly inspection cost

**Key:** cost

**Expr:** hours * rate

**Format:** currency

#### Hours saved by skipping

**Key:** saved

**Expr:** lots * (skip / 100) * (chars * min_char + setup) / 60

**Format:** number

**Chart:**

#### Inspection hours vs skip rate

**Type:** line

**X:** skip

**From:** 0

**To:** 90

**Steps:** 19

**Series:**

- hours

**Disclaimer:** Planning estimate from the inputs you provide. It does not model peaks, rework, retests or training time.

## Content

**Intro:** How many inspectors does incoming and in-process inspection need? The answer is lots times work per lot, reduced by what dynamic modification lets you skip. This calculator makes that arithmetic explicit and shows how skip rules change the headcount.

**Sections:**

#### How to use it

**Body:** Take lots per month from your QM lot list and the average characteristic count from your inspection plans. Estimate time per characteristic from a short time study. Set the share of lots skipped under your dynamic modification rules and the productive hours per inspector, after breaks, training and meetings. The result is hours, FTE and monthly cost.

**Bullets:**

- Use a representative month, not a peak
- Time a few typical lots to set minutes per characteristic
- Keep productive hours realistic, often 120 to 140 per month
- Run the calculation per plant or per inspection type for better accuracy

#### The formula

**Body:** Minutes per inspected lot equals characteristics times minutes per characteristic plus setup plus review time. Inspected lots equal total lots times one minus the skip share. Total hours are inspected lots times minutes per lot divided by 60, plus the review time for skipped lots. FTE equals hours divided by productive hours per inspector. Savings from skipping equal skipped lots times inspection and setup time.

#### Reading the chart

**Body:** The line shows monthly inspection hours as the skip share rises. It falls linearly, because the model treats each skipped lot as saving the same work, but real savings depend on which lots qualify. Skip rules depend on the quality level of each vendor and material, so the savings arrive slowly after rules are introduced and stop if quality drops.

#### Common mistakes

**Body:** Assuming all lots qualify for skipping from day one. Ignoring walk, queue and material handling time in the minutes per characteristic. Forgetting that quality level resets after a reject. Using the result to cut staff without checking the effect on escapes and vendor performance.

**Cta:** If you want inspection workload tracked from live QM lot data rather than estimates, Netray can help you set up that reporting.

**Faq:**

#### Where do I get lots per month?

**Answer:** From the inspection lot list in QM, for example transaction QA32 filtered by plant, creation date and inspection type. Count lots created, not lots closed, if you want the workload to arrive.

#### How realistic is the skip rate?

**Answer:** Start with the share of lots that already qualify under your rules, for example vendors with a long record of accepted lots. A rate higher than that is a target, not a forecast.

#### Does it include sampling?

**Answer:** Sample size is part of characteristics and minutes. If a lot needs five sample units at 12 characteristics each, enter 60 characteristics or an equivalent total.

#### Can I use it for final inspection?

**Answer:** Yes. Replace setup and review with your final inspection overheads, and set skip to zero if your customers require every lot to be inspected.

## Search terms

inspection workload calculator, quality inspector staffing calculator, SAP QM inspection lots per month, skip lot savings calculator, incoming inspection FTE, quality department headcount planning, inspection time per lot, SAP QM dynamic modification savings

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