Though manpower planning models have been part of OR for many years, and simulation has always been acknowledged as a potential approach, there are few reported applications of its use. In this case-based study we report on a micro-simulation model that exploits the structure of the European Commission’s appraisal and promotion rules, and includes regression-based sampling schemes which allow for non-Normal error terms to represent behavioural factors that led to the need for a new system. With a suitably parsimonious formulation the 20,000 person model runs very effectively, and the transparency associated with simulation proves an important factor in the successful use of the model as the basis for designing a promotion box system that was implemented across the Commission in 2009. The simulation modelling incorporates many Markov-type elements, and we reflect on important lessons learned from this combined use of micro-simulation and Markov-based approaches to manpower modelling.