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When the need to establish the number of workers relative to the production volume, is there a formula or guideline to use in order to determine when to bring in more workers?

This is a highly subjective question - is your production seasonal?  Is the increase in production temporary and can you hire skilled temporary labor to cover the increase?  I have worked in various manufacturing industries and never heard of a particular rule of thumb.  I believe your best guidline will be a realistic sales forecast (salespeople are famous for "puffing") in concert with a production schedule.  What you do not want to do is hire people and then have to lay them off in 6 months - make sure the headcount adds are reasonably permanent.  Sorry I can't be more definitive....