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Chapter 11
Strategic Capacity Management
OBJECTIVES
Decision Trees
Capacity Utilization
Capacity used
Capacity utilization rate
Best operating level
Where
Capacity used
Average
unit cost
of output
Underutilization
Overutilization
Best Operating
Level
Volume
During
During one
one week
week of
of production,
production, aa plant
plant
produced
produced 83
83 units
units of
of aa product.
product. Its
Its
historic
historic highest
highest or
or best
best utilization
utilization
recorded
recorded was
was 120
120 units
units per
per week.
week. What
What
is
is this
this plants
plants capacity
capacity utilization
utilization rate?
rate?
Answer:
Answer:
Capacity
Capacity
Capacityutilization
utilizationrate
rate==
Capacityused
used ..
Best
Best operating
operating level
level
==83/120
83/120
=0.69
=0.69or
or 69%
69%
Economies
Economiesof
ofScale
Scaleand
andthe
theExperience
ExperienceCurve
Curveworking
working
Average
unit cost
of output
100-unit
plant
200-unit
plant
300-unit
plant
400-unit
plant
Diseconomies
Diseconomiesof
ofScale
Scalestart
startworking
working
Volume
The
Experience
Curve
As
Asplants
plantsproduce
producemore
moreproducts,
products,they
they
gain
gainexperience
experiencein
inthe
thebest
bestproduction
production
methods
methodsand
andreduce
reducetheir
theircosts
costsper
perunit
unit
Yesterday
Cost or
price
per unit
Today
Tomorrow
Capacity Focus
10
Capacity Flexibility
Flexible plants
Flexible processes
Flexible workers
Units
per
month
Stage 1
Stage 2
Stage 3
6,000
7,000
5,000
Maintaining System Balance: Output of one stage is
the exact input requirements for the next stage
Balanced
Balancedstages
stagesof
ofproduction
production
Units
per
month
Stage 1
Stage 2
6,000
6,000
Stage 3
6,000
11
12
Capacity Planning
Determining Capacity
Requirements
13
14
50
35
60
50
80
70
100
90
100
80
110
90
120
100
140
110
Question:
Question: Are
Are we
we really
really producing
producing two
two
different
different types
types of
of mustards
mustards from
from the
the
standpoint
standpoint of
of capacity
capacity requirements?
requirements?
Answer:
Answer: No,
No, its
its the
the same
same product
product just
just
packaged
packaged differently.
differently.
15
16
1
150
115
2
170
140
3
200
170
4
240
200
17
Question:
Question:What
Whatare
arethe
theYear
Year11values
valuesfor
forcapacity,
capacity,machine,
machine,
and
andlabor?
labor?
Year:
Small (000s)
Family (000s)
1
150
115
2
170
140
3
200
170
4
240
200
Small
Mach. Cap.
300,000
Labor
6
Family-size
Mach. Cap.
240,000
Labor
6
150,000/300,000=50%
At 1 machine for 100,000, it
Small
takes 1.5 machines for 150,000
Percent capacity used
50.00%
Machine requirement
1.50
Labor requirement
3.00
At 2 operators for
Family-size
100,000, it takes 3
operators for 150,000
Percent capacity used
47.92%
Machine requirement
0.96
Labor requirement
2.88
The McGraw-Hill Companies, Inc.,
18
Question:
Question:What
Whatare
arethe
thevalues
valuesfor
forcolumns
columns2,
2,33and
and44in
inthe
thetable
tablebelow?
below?
Year:
Small (000s)
Family (000s)
Small
Family-size
Small
Percent capacity used
Machine requirement
Labor requirement
Family-size
Percent capacity used
Machine requirement
Labor requirement
1
150
115
2
170
140
3
200
170
4
240
200
Mach. Cap.
Mach. Cap.
300,000
240,000
Labor
Labor
6
6
50.00%56.67%
1.501.70
3.003.40
66.67%
2.00
4.00
80.00%
2.40
4.80
58.33%
47.92%
1.17
0.96
3.50
2.88
70.83%
1.42
4.25
83.33%
1.67
5.00
19
20
A
B
C
0.1
Low
10
-120
20
0.5
Medium
50
25
40
0.4
High
90
200
60
21
A
B
C
22
Rs90k
Rs50k
Rs10k
Rs200k
Rs25k
-Rs120k
Rs60k
Rs40k
Rs20k
23
Rs62k
Rs62k
AA
High
Highdemand
demand(0.4)
(0.4)
Medium
Mediumdemand
demand(0.5)
(0.5)
Low
Lowdemand
demand(0.1)
(0.1)
Rs90k
Rs90k
Rs50k
Rs50k
Rs10k
Rs10k
EV
EVAA=0.4(90)+0.5(50)+0.1(10)=Rs62k
=0.4(90)+0.5(50)+0.1(10)=Rs62k
24
Rs62k
A
B
Rs80.5k
Rs46k
Rs90k
Rs50k
Rs10k
Rs200k
Rs25k
-Rs120k
Rs60k
Rs40k
Rs20k
Alternative
AlternativeBBgenerates
generatesthe
thegreatest
greatestexpected
expectedprofit,
profit,so
so
our
ourchoice
choiceis
isBBor
orto
toconstruct
constructaanew
newfacility
facility
25
26
27
Question Bowl
The objective of Strategic Capacity
Planning is to provide an approach
for determining the overall capacity
level of which of the following?
a. Facilities
b. Equipment
c. Labor force size
d. All of the above
e. None of the above
28
Question Bowl
To improve the Capacity Utilization Rate we can do
which of the following?
a.
b.
c.
d.
e.
29
Question Bowl
When we talk about Capacity Flexibility which
of the following types of flexibility are
included?
a. Plants
b. Processes
c. Workers
d. All of the above
e. None of the above
30
Question Bowl
When adding capacity to existing operations which of
the following are considerations that should be
included in the planning effort?
a.
b.
Frequency of additions
c.
External sources
d.
e.
31
Question Bowl
Which of the following is a term used to describe
the difference between projected capacity
requirements and the actual capacity
requirements?
a.
Capacity cushion
b.
Capacity utilization
c.
d.
e.
32
Question Bowl
In determining capacity requirements we must do
which of the following?
a.
b.
c.
d.
e.
33
Question Bowl
In a Decision Tree problem used to evaluate
capacity alternatives we need which of the
following as prerequisite information?
a.
b.
Payoff values
c.
A tree
d.
e.
Answer: b. Payoff
values (Expected
values are what is
computed, not
prerequisite to the
analysis.)