CAPACITY PLANNING
Overview
Capacity Planning is the process of determining the required people, machines and physical resources needed to meet the production objectives. It is concerned with the long and medium time ranges.
In the long range, top management approval is needed to make decisions on resources that take a long time to acquire or dispose (e.g., land, facilities, machines, equipment and work force).
The long range capacity planning is dictated by the production plan and Master Production Schedule (MPS). The long range resource requirements planning is sometimes referred to as rough cut planning.
Medium range capacity planning centers around decisions concerning make/buy, hire/layoff and acquiring additional tooling. This function relates to the detailed material requirements where the objective is to achieve detailed individual part number schedules as established by MRP. To accomplish this, the overall capacity of each work center and vendor must be known. It is the objective of medium range planning to adjust factors that determine capacity until the required computed capacity is in balance with the available capacity of the plant, work centers and vendors.
Capacity Requirements Planning is the technique for estimating the period by period load on work centers. The detailed MRP plan and shop routing files are used to estimate the capacity loads. Capacity Requirements Planning (CRP) is an interactive process of projecting capacity availability and comparing with future requirements.
Work Center/Routing
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Allows for online data entry and retrieval of capacity planning information
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Maintain time standards for each work step. These can be MTM Industrial Engineered standards or accurate estimates based on experience.
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Maintain process routings for product groups and job types. These routings should be modular in design to accommodate alternate processing steps for certain jobs.
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Maintain work center definitions for all work centers at all facilities. Typical data elements include facility ID, department ID, sub-department ID, machine group ID and machine ID.
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Maintain standard indirect labor and processing times to accommodate setup time, run time, queue time, move time and wait time.
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Maintains integrated capacity plans:
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Rough cut capacity planning using resource profiles, bills, or labor, etc. for specific products and product groupings
-
CRP using MRP output
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Supports userdefined planning time fences
-
Maintain multiple alternate routings for a part
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Maintain alternate operations for a routing step
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Maintain input/output standards for each:
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Machine
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Work center
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Department
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Facility
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Establish input/output standards by:
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Units
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Rate
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Units or rate by product class/type
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Allows units of capacity to be user defined
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Express production rates for operations as standard hours/unit or hours for the operation
-
Maintain both long range and medium range capacity planning systems
-
Performs both infinite and finite loading of shop orders
-
Performs finite scheduling (operation sequencing) simulation capability to determine the completion date of work orders
-
Generate a "rough cut" capacity plan using a proposed MPS
-
•Identifies all resources that are projected to be capacity constrained and the work orders that are scheduled to be processed by those resources
-
Check availability of materials and capacity before shop orders are issued
-
•Allows temporary capacity changes
-
Overlap operation scheduling (jobs start in another work center before the previous center has completed the run) when performing capacity load analysis
-
Generate a final capacity plan using MRP requirements output by:
-
Department
-
Work center
-
Machine
-
Outside contractor
-
Uses output of MRP and current orders to calculate duration of work at work centers using the following:
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Due dates
-
Order quantities
-
Standard setup
-
Run-times
-
Transit times
-
Queue times
-
Supports automatic regeneration from MRP
-
Calculate the final production plan using finite loading and infinite loading
-
Display the capacity plan for selected:
-
Departments
-
Work centers
-
Machines
-
Outside contractors
-
Supports loading work centers individually based on the appropriate combination of setup, run labor and/or machine time
-
Display online work center load in either summary or detail format
-
Supports user defined work center description
-
Allows for different capacity load method by work center
-
Display online the capacity plan for some user specified date range
-
Generate a resource requirements plan utilizing bill of resources or equivalent and input from forecast or MPS
-
Supports user defined shop calendars by work center to alter capacity availability by day over and above standard capacity and to schedule operations during loading
-
Reschedules backlogs and past due orders so the revised dates can provide feedback to the master schedule
-
Compare time phased work center load to available capacity and report on under/over load conditions. The work center load can be the following:
-
Actual load (released orders)
-
Planned load (including MRP planned orders and unreleased orders)
-
Both actual and planned
-
Simulate the effects on capacity and resource requirements by:
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Introducing time phased changes to sales forecast or master schedule
-
Introducing time phased changes in available capacity (e.g., additional shift is available, new facility becomes operational, etc.)
-
Introducing bill of resource effectivity dates
-
Measure work centers to provide resource utilization data by:
-
Machine
-
Employee/labor
-
Capacity
-
Report on planned to actual input/output by:
-
Machine
-
Work center
-
Department
-
Facility
-
Provides for the identification of critical, capacity constrained resources
-
Distribute the work load remaining on incomplete operations into the actual time periods in which they are scheduled when performing capacity load analysis
-
Identify rework operations when performing input/output planning, capacity planning and job scheduling
-
Allows for backward scheduling of actual and planned operations
-
Display online for a given work center:
-
Planned load
-
Firm load
-
Released load
-
Current load
-
Display the capacity available in a department, work center, machine or outside contractor by time period
-
Ability for the capacity load requirements record to contain, at a minimum, for the following:
-
Part number
-
Operation start date
-
Setup hours
-
Run hours
-
Work order number
-
Work center
-
Machine number
-
Department
-
Provides the capability to measure work centers to provide resource utilization data
-
Has the ability to distribute the work remaining on incomplete operations into the actual time periods in which they are scheduled
-
Provides capacity planning simulation to allow the schedulers to review the impact of their proposed changes without modifying the existing schedule
-
Allows for different efficiency percentages by work center in scheduling and loading
-
Allows actual and/or standard overhead costing methods to be specified for a work center
-
Maintains both machine and labor capacity information by work center
-
Allows the user to specify the number of machines, number of shifts, and hours per shift for standard capacity
-
Allows the user to set a minimum unit of capacity for a work center
-
Provides for input/output tolerances to be set up to filter exceptions in planned versus actual input, output and queue levels.
Allows for online data entry and retrieval of capacity planning information
Maintain time standards for each work step. These can be MTM Industrial Engineered standards or accurate estimates based on experience.
Maintain process routings for product groups and job types. These routings should be modular in design to accommodate alternate processing steps for certain jobs.
Maintain work center definitions for all work centers at all facilities. Typical data elements include facility ID, department ID, sub-department ID, machine group ID and machine ID.
Maintain standard indirect labor and processing times to accommodate setup time, run time, queue time, move time and wait time.
Maintains integrated capacity plans:
- Rough cut capacity planning using resource profiles, bills, or labor, etc. for specific products and product groupings
- CRP using MRP output
Supports userdefined planning time fences
Maintain multiple alternate routings for a part
Maintain alternate operations for a routing step
Maintain input/output standards for each:
- Machine
- Work center
- Department
- Facility
Establish input/output standards by:
- Units
- Rate
- Units or rate by product class/type
Allows units of capacity to be user defined
Express production rates for operations as standard hours/unit or hours for the operation
Maintain both long range and medium range capacity planning systems
Performs both infinite and finite loading of shop orders
Performs finite scheduling (operation sequencing) simulation capability to determine the completion date of work orders
Generate a "rough cut" capacity plan using a proposed MPS
•Identifies all resources that are projected to be capacity constrained and the work orders that are scheduled to be processed by those resources
Check availability of materials and capacity before shop orders are issued
•Allows temporary capacity changes
Overlap operation scheduling (jobs start in another work center before the previous center has completed the run) when performing capacity load analysis
Generate a final capacity plan using MRP requirements output by:
- Department
- Work center
- Machine
- Outside contractor
Uses output of MRP and current orders to calculate duration of work at work centers using the following:
- Due dates
- Order quantities
- Standard setup
- Run-times
- Transit times
- Queue times
Supports automatic regeneration from MRP
Calculate the final production plan using finite loading and infinite loading
Display the capacity plan for selected:
- Departments
- Work centers
- Machines
- Outside contractors
Supports loading work centers individually based on the appropriate combination of setup, run labor and/or machine time
Display online work center load in either summary or detail format
Supports user defined work center description
Allows for different capacity load method by work center
Display online the capacity plan for some user specified date range
Generate a resource requirements plan utilizing bill of resources or equivalent and input from forecast or MPS
Supports user defined shop calendars by work center to alter capacity availability by day over and above standard capacity and to schedule operations during loading
Reschedules backlogs and past due orders so the revised dates can provide feedback to the master schedule
Compare time phased work center load to available capacity and report on under/over load conditions. The work center load can be the following:
- Actual load (released orders)
- Planned load (including MRP planned orders and unreleased orders)
- Both actual and planned
Simulate the effects on capacity and resource requirements by:
- Introducing time phased changes to sales forecast or master schedule
- Introducing time phased changes in available capacity (e.g., additional shift is available, new facility becomes operational, etc.)
- Introducing bill of resource effectivity dates
Measure work centers to provide resource utilization data by:
- Machine
- Employee/labor
- Capacity
Report on planned to actual input/output by:
- Machine
- Work center
- Department
- Facility
Provides for the identification of critical, capacity constrained resources
Distribute the work load remaining on incomplete operations into the actual time periods in which they are scheduled when performing capacity load analysis
Identify rework operations when performing input/output planning, capacity planning and job scheduling
Allows for backward scheduling of actual and planned operations
Display online for a given work center:
- Planned load
- Firm load
- Released load
- Current load
Display the capacity available in a department, work center, machine or outside contractor by time period
Ability for the capacity load requirements record to contain, at a minimum, for the following:
- Part number
- Operation start date
- Setup hours
- Run hours
- Work order number
- Work center
- Machine number
- Department
Provides the capability to measure work centers to provide resource utilization data
Has the ability to distribute the work remaining on incomplete operations into the actual time periods in which they are scheduled
Provides capacity planning simulation to allow the schedulers to review the impact of their proposed changes without modifying the existing schedule
Allows for different efficiency percentages by work center in scheduling and loading
Allows actual and/or standard overhead costing methods to be specified for a work center
Maintains both machine and labor capacity information by work center
Allows the user to specify the number of machines, number of shifts, and hours per shift for standard capacity
Allows the user to set a minimum unit of capacity for a work center
Provides for input/output tolerances to be set up to filter exceptions in planned versus actual input, output and queue levels.
Reports
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Capacity Planning Report – Details by department, work center, machine, operation and outside contractor on the released and planned load, and available capacity by time period.
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Detail Load Report – Lsts by work center, part number, work order and operation number on the scheduled start/finish dates and quantities complete/incomplete
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Summary Load Report – Lists by work center and machine the planned load, firm load and released load
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Routings List – Lists operations required to produce each subassembly and finished goods items, as well as machine center, standard run, setup, queue, and wait times
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No Activity Report – Lists each open order that has not had any shop activity reported since a specified date
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Work Center/Department Current Workload Report – Lists all open orders on a priority or due date sequence which are in queue at the work center or the department
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Resource Utilization Report – Measures the utilization of equipment in machine groups and work centers. The report summarizes results by department and facility.
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Lead Time Report – Automatically calculates the lead time roll up for all orders at a work center and builds new lead times for setting due dates on new orders, sequenced by item
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Work Center Scheduled Load Report – Lists each scheduled job within each work center broken down into weekly periods. This detail can be extended out to a meaningful horizon, typically two to four weeks. Data elements could include item number, order number,order status, operation start date and capacity statistics
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Input/Output Planning Report – Lsts by work center and/or department the actual input and output and compares to the planned input and output for the same time period
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Work Center Listing – Lists all work center data elements on the work center master file
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Rough Cut Planning Report – Lists planned capacity requirements based on MPS and bills of resources. In addition, highlights the underutilized and constrained facilities, departments and work centers
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Available Capacity Report – Displays the capacity available in a department, work center, machine or outside contractor by time period.
Capacity Planning Report – Details by department, work center, machine, operation and outside contractor on the released and planned load, and available capacity by time period.
Detail Load Report – Lsts by work center, part number, work order and operation number on the scheduled start/finish dates and quantities complete/incomplete
Summary Load Report – Lists by work center and machine the planned load, firm load and released load
Routings List – Lists operations required to produce each subassembly and finished goods items, as well as machine center, standard run, setup, queue, and wait times
No Activity Report – Lists each open order that has not had any shop activity reported since a specified date
Work Center/Department Current Workload Report – Lists all open orders on a priority or due date sequence which are in queue at the work center or the department
Resource Utilization Report – Measures the utilization of equipment in machine groups and work centers. The report summarizes results by department and facility.
Lead Time Report – Automatically calculates the lead time roll up for all orders at a work center and builds new lead times for setting due dates on new orders, sequenced by item
Work Center Scheduled Load Report – Lists each scheduled job within each work center broken down into weekly periods. This detail can be extended out to a meaningful horizon, typically two to four weeks. Data elements could include item number, order number,order status, operation start date and capacity statistics
Input/Output Planning Report – Lsts by work center and/or department the actual input and output and compares to the planned input and output for the same time period
Work Center Listing – Lists all work center data elements on the work center master file
Rough Cut Planning Report – Lists planned capacity requirements based on MPS and bills of resources. In addition, highlights the underutilized and constrained facilities, departments and work centers
Available Capacity Report – Displays the capacity available in a department, work center, machine or outside contractor by time period.
Interfaces
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Material Requirements Planning – Provides capacity planning analysis with due date and quantity information on planned and firm work orders
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Shop Floor Control – Provides status information on firm planned, released and inprocess work orders. In addition, SFC provides routings and work center information
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Master Production Schedule – Provides a valid schedule of end items to be produced by time period
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Bill of Materials – Provides bill of resources or bills of labor of capacity planning
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Production Activity Control – Provides status information on released and in process work orders
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Routings – Uses routings to determine work center loads. Uses alternate routings and alternate operations to optimize load
-
Order Entry/Quotations – Provides capacity information.
Material Requirements Planning – Provides capacity planning analysis with due date and quantity information on planned and firm work orders
Shop Floor Control – Provides status information on firm planned, released and inprocess work orders. In addition, SFC provides routings and work center information
Master Production Schedule – Provides a valid schedule of end items to be produced by time period
Bill of Materials – Provides bill of resources or bills of labor of capacity planning
Production Activity Control – Provides status information on released and in process work orders
Routings – Uses routings to determine work center loads. Uses alternate routings and alternate operations to optimize load
Order Entry/Quotations – Provides capacity information.
Field Sizes
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Work center number/type
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Work center description
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Work/Job order number
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Operation number
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Routing location number
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Number of shifts
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Hours per shift
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Number of machines
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Number of people per shift
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Capacity per shift
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Efficiency
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Labor rate
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Overhead rate
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Machine overhead rate
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Setup rate dollars per hours
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Setup hours at standard
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Set up hours at actual
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Run hours at standard
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Run hours at actual
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Change over standard hours
- Change over actual hours.
Work center number/type
Work center description
Work/Job order number
Operation number
Routing location number
Number of shifts
Hours per shift
Number of machines
Number of people per shift
Capacity per shift
Efficiency
Labor rate
Overhead rate
Machine overhead rate
Setup rate dollars per hours
Setup hours at standard
Set up hours at actual
Run hours at standard
Run hours at actual
Change over standard hours
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