DHL Yard & Shuttle Estimator v14.1

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Username (DHL ID) Your DHL employee ID or network login

Password Your DHL network password

Credentials are used for identification purposes only and are not transmitted or stored outside this browser session.

P Project Information Fill in project details before running calculations

New project — name will be versioned automatically as Project Name_V1

Project Name Base name — version suffix added automatically

V1

Customer Name End customer or prospect this estimate is for

Location Site city, state or facility address

Sector DHL Supply Chain industry vertical

Notes / Assumptions Optional — key assumptions, data sources, or scope notes for this estimate

Project fields appear on the Results tab header and in exported files.

Operation Type:

Yard operations — inputs and outputs for yard truck activity only.

AOperations Overview

Days of Operation / Week

DOT/HOS Cap: 60 hrs/week. Set duty hours in Section C. A warning appears in Results when duty hours exceed this limit.

Daily Volume

Trips / Day

Shifts / Day

BShift Timings & Pre/Post Time Pre-shift = inspection + briefing | Post-shift = handover | Refuel = end-of-shift fuelling | All reduce productive hours

▸ Shift 1

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

▸ Shift 2

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

▸ Shift 3

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

CDriver Parameters

Workforce

Duty Hrs / Driver / Week

Driver Availability % sick, training, vacation

Buffer / Spare % breakdown contingency

Efficiency & Fleet

Productive Time % of available window

Trailer Pool Ratio

Equipment Sharing Across Shifts same PU reused between shifts

Trip Distribution

Trips / Shift Distribution

DTrip Time Components Times in minutes, calculated in hours | Drive time: enter Distance+Speed or direct minutes

Origin Side

a) Drive — Origin → Dest

Drive Time (min)

b) Origin Processing (min) gate, paperwork, queue

c) Loading Time (min)

d) Misc — Origin (min) staging, delays, other

Destination Side

e) Drive — Dest → Origin

Drive Time (min)

f) Dest. Processing (min) check-in, wait, dock

g) Unloading Time (min)

h) Misc — Dest (min) reposition, yard moves

Effective Trip Time

Component Breakdown (hours)

Total (a→h) in hours

—

Drive time: enter Distance & Speed for auto-calc, or switch to Manual to type minutes directly. Times input in minutes, shown in hours.

AOperations Overview🚛 Shuttle — trip mode shared with Yard

Days of Operation / Week

DOT/HOS Cap: 60 hrs/week. Set duty hours in Section C. A warning appears in Results when duty hours exceed this limit.

Daily Volume

Trips / Day

Shifts / Day

BShift Timings & Pre/Post Time Pre-shift = inspection + briefing | Post-shift = handover | Refuel = end-of-shift fuelling | All reduce productive hours

▸ Shift 1

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

▸ Shift 2

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

▸ Shift 3

Start Time

End Time

Duration

—

Pre-Shift (min)

Post-Shift (min)

Break (min)

Refuel (min) at end of shift

Productive Hrs

—

Trips Possible

—

CDriver Parameters

Workforce

Duty Hrs / Driver / Week

Driver Availability % sick, training, vacation

Buffer / Spare % breakdown contingency

Efficiency & Fleet

Productive Time % of available window

Trailer Pool Ratio

Equipment Sharing Across Shifts same PU reused between shifts

Trip Distribution

Trips / Shift Distribution

DTrip Time Components Times in minutes, calculated in hours | Drive time: enter Distance+Speed or direct minutes

Origin Side

a) Drive — Origin → Dest

Drive Time (min)

b) Origin Processing (min) gate, paperwork, queue

c) Loading Time (min)

d) Misc — Origin (min) staging, delays, other

Destination Side

e) Drive — Dest → Origin

Drive Time (min)

f) Dest. Processing (min) check-in, wait, dock

g) Unloading Time (min)

h) Misc — Dest (min) reposition, yard moves

Effective Trip Time

Component Breakdown (hours)

Total (a→h) in hours

—

Drive time: enter Distance & Speed for auto-calc, or switch to Manual to type minutes directly. Times input in minutes, shown in hours.

1Per-Shift Summary

Run calculations to see results.

2Total Resource Requirements

Drivers/Peak Day

—

Operational

Power Units

—

Active fleet

Trailer Pool

—

Total trailers

Drivers + Buffer

—

With spare %

Hiring Target (FTE)

—

incl. avail & buffer

Peak Shift Drivers

—

Busiest shift

Avg Scheduled Hrs/Driver/Wk

—

weighted avg across roster

3Trip Time & Utilization Detail

Run calculations to see results.

3Weekly Driver & Power Unit Schedule

S1S2S3 Power UnitOFF/PM

Run calculations first.

4 Weekly Activity Gantt — Driver & Equipment 7-day timeline · activity bars per shift · click any row for detailed timetable

Run calculations to generate the Gantt chart.

★Realism Checks

Run calculations to generate suggestions.

+Additional Variables to Consider

🔄

Cycle Time Variability
Drive, load, and processing times vary ±15–20%. Peak-hour congestion can add 20–30% to drive time.

🚧

Dock & Bay Constraints
Dock doors limit simultaneous loading. If concurrent trips exceed docks, queuing inflates processing time.

⛽

Fueling Time
If fueling happens mid-shift, add 10–15 min to post-shift or it becomes invisible in your estimates.

🔁

Driver Turnover
Yard driver turnover averages 60–90% annually. Build a recruitment pipeline into headcount planning.

🛠

Maintenance Downtime
Power units need PM ~1–2 days/month. Factor 5–8% of fleet unavailable at any time.

📡

Technology Gaps
Without GPS/TMS, dispatch inefficiency adds 10–15% to actual trip times vs. estimated.

?How to Use This Tool

① Section A — Operations Overview

Enter Trips/Day (total across all shifts), Shifts/Day (1–3), and Days of Operation. Choose Single Daily, By Weekday, or Hourly trip mode. In Hourly mode, fill in the 7×24 volume grid.

② Section B — Shift Timings

Set Start/End times for each active shift. Duration auto-calculates including overnight crossings. Enter Pre-shift, Post-shift, Break and Refuel in minutes — all four reduce the productive window. Productive Hrs and Trips Possible update live.

③ Section C — Driver Parameters

Duty Hrs/Driver/Week is the key constraint — it determines how many shifts each driver works per week (⌊duty_hrs ÷ shift_duration⌋) and how many FTE are hired per shift. Set Availability % and Buffer % for realistic staffing. Each shift is staffed independently from its own FTE pool.

④ Section D — Trip Time Components

Enter all times in minutes. For each drive leg (a and e), choose Manual (min) to type directly or Dist + Speed to auto-calculate from miles and mph. Components a–h are summed into T_eff shown in Column 3. The breakdown tiles update live.

⑤ Run Calculations

Click ▶ Run Calculations. A ⚠ Re-run badge appears if you change any input after calculating — always re-run before reading outputs. The engine splits trips as ⌈trips ÷ shifts⌉ per shift (both shifts plan for worst case), then derives drivers per shift, then FTE per shift independently.

⑥ Reading the Outputs

Results: Per-shift table + resource cards. Schedule: Full weekly roster — drivers numbered 01–N, grouped by shift. Off-days rotate per pool. Hourly/Gantt: Driver numbers match Schedule exactly. Greyed rows + red dashed line show roster surplus above the 6-needed operational floor. Suggestions: Realism checks on all parameters.

Understanding the Gantt Chart

Yellow = Pre/Post-Shift overhead Red = Refuel ⛽ Faded = Productive window White notch = Break Solid bars = Trip activity Greyed rows + ─── red line = roster surplus above operational need PU rows show S1/S2 labels when equipment is shared across shifts Driver numbers in Gantt = Driver numbers in Schedule tab exactly

🔍

⬆Batch Import

Upload CSV with one scenario per row. Mode auto-detected from columns: flat (trips_day), weekly (t_mon–t_sun), hourly (h_mon_06 etc).

📂

Drop CSV or click to browse

Flat: trips_day, shifts_day… | Weekly: add t_mon–t_sun | Hourly: add h_mon_06, h_mon_07…

⬇Export

Export results to CSV for analysis in Excel or other tools.