week 12,1-2 dan 13 capacity planning
TRANSCRIPT
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Capacity Planning
Week 12,1-2 dan 131
Capacity definition2
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
Capacity Requiredcapacity needed toproduce a desired output in a given time period
Capacity Planningdetermining the resourcesand methods needed to meet the priority plan
Capacity Controlmonitoring production,comparing with the capacity plan, and takingappropriate corrective actions
Capacity Managementdetermining capacity
needed as well as providing, monitoring, andcontrolling the capacity
Capacity versus Load
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Capacity Planning Levels
Resource PlanningLong range resource
requirements linked to the production plan
Rough-cut Capacity PlanningUsed to check
feasibility of MPS
Capacity Requirements PlanningDetailed
work center capacity plans linked to MRP
Capacity Planning Levels
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Capacity Requirements Planning (CRP)
Inputs
Open Order Filefound as scheduled receipts on
MRP
Planned order releases from MRPPotential
future orders
Work Center file
Information on capacity in the work center
Move, wait, and queue time information
Capacity Requirements PlanningInputs - Continued
Routing filethe 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 calender11
Finding Capacity Available
Rated Capacity = (available time) x (utilization) x
(efficiency)
Available timenumber 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)13
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 capacity14
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)15
Capacity required (load)16
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Capacity LoadSum 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 schedulingLaunch 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 104 days in work center 12
Operation 205 days in work center 14
Operation 301 day in work center 17
Operation 402 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 PlanAdjusting 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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