CAPACITY PLANNING
Prof. Dr. Orhan Torkul
Res. Assist. M. Raşit Cesur
Capacity Planning
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Manufacturing planning and control system includes two main activities,
material and capacity planning and control.
These two main activities shoulb be in a harmony while determining market
needs for utulizing manufacturing planning and control system maximum.
A critical activitiy that parallels developing material plans is developing
capacity plans.
Capacity Planning Process
Long range
Resource
planning
Production
planning
Rough-cut
capacity
planning
Master
production
scheduling
Demand
management
Capacity Planning Process
Medium range
Capacity
requirements
planning
Detailed material
planning
Short Range
Finite loading
Input/Output
Analysis
Shop – floor
systems
Vendor systems
Capacity Planning Process
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Resource planning is the decision of using capacity, covers largest planning
horizon.
Resource planning consists of monthly, 3 months period or yearly data
transformation from sales and operations plans for resources like facility
layout, gross workforce, and machinery hours.
MPS is basic information resource for capacity planning.
Finite loading, is controlling material folw for optimum capacity usage.
Input output analysis: Monitoring capaciy when capacity plans are performed.
Basic Concepts
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Work centre: Place where product and service is produced.
Operation : Actions which are performed for production of product or service.
Route: The list in which operations are recorded by sequence for producing
product.
Processing time: The time that production operations take.
Setup time: The time of setting work centre up which isn’t related to amounth
of product.
Coffee Table Production Process
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Chipboard sheets are cutted into smaller pieces that are needed for
production of cıffee table. This is called cutting process.
Cutted chipboards which are used for production of top plate are covered
with PVC on four side. This process is called edge banding.
Finally, all pieces are drilled for assembly in derilling operation and assembled
together in assembly operation.
Furniture Production Videos
BOM of Coffee Table
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All processing time defined below, are for production of 1 unit. 4 legs and 4
curtains are needed for production of 1 coffee table.
Parent
COFFEE
TABLE
TOP PLATE
Route
Assembly (60 min)
Cutting (40 min), Edge Banding (80
min), Drilling (10 min)
LEG
Cutting (10 min), Drilling(10 min)
SKIRT
Cutting (10 min), Edge Banding (10
min),Drilling(10 min)
Child
Amounth
TOP PLATE
1
LEG
4
SKIRT
4
CHIPBOARD
0.64 m2
PVC
3.2 m
WOODDEN BAR
1
SCREW
2
CHIPBOARD
0.06 m2
PVC
0.6 m
Capacity Planning and Control Techniques
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Capacity planninh with general factors;
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Data is suplied from MPS.
Generally old and well known data and standart data are used.
Capacity of facility and machine capacities are calculated.
Calculations are detailed by calculating capacities of work centers..
There isn’t large amounth of data entry needed.
Easy to calculate.
It’s feasible when products are similar.
Example of General Factors
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All components of coffee table are processed in cutting 120 mins
(40+4x10+4x10), edge banding 120 mins, drilling 90 mins and assembly 60
mins.
Planned products after MRP run;
Ürün
Hafta 1 Hafta 2
Hafta 3
Hafta 4
Hafta 5
Hafta 6
Hafta 7
Hafta 8
COFFEE TABLE
8
13
18
17
19
22
25
18
Work Center
Processing Time(hours)
Cutting
16
36
26
36
34
38
44
50
Edge Banding
16
36
26
36
34
38
44
50
Drilling
12
27
19.5
27
25.5
27.5
33
37.5
Assembly
8
18
12
18
17
19
22
25
Capacity Planning and Control Techniques
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Capacity records;
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Capacities of workcenters with the detail of products in MPS are calculated by this
technique.
It requires more data then general factors.
Material records and detailed routes are needed.
All operation times are needed for every machine performing the operation.
This metod enables for more detailed capacity plannig for every workcenters.
Example of Capacity Record
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Capacity is calculated for every single piece of product.
Product
Week 1 Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
COFFEE TABLE
8
13
18
17
19
22
25
22
25
18
Work Center
Assembly
Processing Time(hour)
8
18
13
18
17
19
Example of Capacity Record
Product
Week 1 Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
TOP PLATE
8
13
18
17
19
22
25
18
Work Center
Processing Time(hours)
Cutting (40 min)
5.33
12
8.67
12
11.33
12.67
14.67
16.67
Edge Banding (80 min)
10.67
24
17.33
24
22.67
25.33
29.33
33.33
Drilling (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
Example of Capacity Record
Product
Week 1 Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
LEG
8
13
18
17
19
22
25
18
Work Center
Processing Time(hour)
Cutting (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
Drilling (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
Example of Capacity Record
Product
Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
SKIRT
8
18
13
18
17
19
22
25
Work Center
Processing Time(hour)
Cutting (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
Edge Banding (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
Drilling (10 min)
1.33
3
2.17
3
2.83
3.17
3.67
4.17
THANKS