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Week 12,1-2 dan 13

Capacity Planning

Capacity definition
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Capacity is the amount of work that can be done in a specified time period. capacity is defined as the capability of a worker, machine, work center, plant, or organization to produce output per time period. Capacity is a rate of doing work, not the quantity of work done.

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Basic Capacity Definitions

produce a desired output in a given time period Capacity Planning determining the resources and methods needed to meet the priority plan Capacity Control monitoring production, comparing with the capacity plan, and taking appropriate corrective actions Capacity Management determining capacity needed as well as providing, monitoring, and controlling the capacity

Capacity Required capacity needed to

Capacity versus Load

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Capacity Planning Levels

Resource Planning Long range resource

requirements linked to the production plan

Rough-cut Capacity Planning Used to check

feasibility of MPS

Capacity Requirements Planning Detailed

work center capacity plans linked to MRP

Capacity Planning Levels

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Capacity Requirements Planning (CRP) Inputs

Open Order File found as scheduled receipts on

MRP

Planned order releases from MRP Potential

future orders

Work Center file

Information

on capacity in the work center Move, wait, and queue time information

Capacity Requirements Planning Inputs - Continued

Routing file the path that the work will follow

Operations

to be performed Operation sequence Work centers used Potential alternative work centers Tooling needed Standard setup times and run times

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Sample Routing File

Figure 5.3 Routing file

Capacity Available

Impacted by:
Product

specification Product mix Methods used to make product Pace of work

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Planning calender
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Finding Capacity Available

Rated Capacity = (available time) x (utilization) x (efficiency)

Available

time number of hours a work center can be

used Utilization = [(hours worked)/(available hours)] x 100% Efficiency = [(actual production rate)/(standard production rate)] x 100%

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Soal (rated capacity)

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A work center consists of 4 machines and is operated 8 hours per day for 5 days a week. Historically, the utilization has been 85% and the efficiency 110%. What is the rated capacity?

Demonstrated capacity
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Over the previous 4 weeks, a work center produced 120, 130, 150, and 140 standard hours of work. What is the demonstrated capacity of the work center?

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Capacity required (load)

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Capacity required (load)

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Capacity Load Sum of all time required for orders on a work center - Example

Example Load Profile

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Scheduling Orders

Back scheduling (the typical approach) Start

with the due date, use lead time to find the proper start date for each operation

Forward scheduling Launch the order into

the first (gateway) work center, then use the lead times to find when the order will be completed at each work center

Back Scheduling Example

An order for 150 of a component is due on day 135 An order starts at the beginning of a day and finished at the end of a day Operation times for the 150 ordered:

Operation 10 4 days in work center 12 Operation 20 5 days in work center 14 Operation 30 1 day in work center 17 Operation 40 2 days in work center 03

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Data from the work center file

The resulting work schedule

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The work schedule shown graphically

Making the plan

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Managing the Plan Adjusting Capacity

Use Overtime or Undertime Adjust the number of workers Shift workers from other work centers Use alternative work centers to shift load Subcontract work

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