CAPACITY PLANNING Teknik Industri Universitas Brawijaya
Referensi Wiratno, S. E., Lecture PPT: Capacity Planning, IE-ITS, 2009. • Smith, Spencer B., Computer-Based Production and Inventory Control, Prentice-Hall, 1989.
Definition • Capacity is the rate at which a productive system can produce
Capacity Planning Process Prepare production schedule
Determine required capacity
Required capacity = Available capacity ? Plan adjusted capacity No
Capacity plan satisfactory
STOP
Yes
STOP
The Hierarchy of Capacity Planning Resource Planning
Production planning
Rough-cut Capacity planning
Master Production scheduling (MPS)
Capacity Requirement planning
Demand management
Material requirements planning (MRP)
Finite Loading
Input/output analysis
Shop floor control (SPC)
Vendor follow-up systems
The Relationship of Capacity Plan with Production Plan Resource plan
Production plan
Planning horizon Long
Rough-cut capacity plan
Master production schedule
Capacity requirements plan
Material requirement plan
Resource plan
Long medium
Rough-cut Capacity plan Capacity requirements plan
Medium short
Plant Production activity control
Department
Work center
Degree of detail
Resources Planning • Determines the resource needed to meet Production Plan
• The longest planning horizon (5 years) • Time bucket : month • Planning the capacity of departments or plant • Main purpose is to change or not the capacity of departments or plant (plant expansion)
• Method : Capacity Planning Factor
Rough-cut Capacity Planning • Determines the capacity required to meet MPS
• Planning horizon : the same as the MPS • Time bucket : week • Planning the capacity of departments or work centers • Main purpose is to change or not the capacity of work centers (acquire to new machine tools)
• Method : Bill of Capacity
Capacity Requirement Planning • Determines the capacity required to meet MRP
• Planning horizon : the same as the MRP • Time bucket : week • Planning the loads of machines or work centers
• Take into account : inventory and lot sizing • Main purpose : authorization of overtime or selection of alternative machines
• Method : Capacity Requirement Planning
Capacity Planning Factors (1) • Example : • Total standard hours produced last quarter 840 • Number of units of product produce last quarter 120 • Average standard hours per unit = 7.0
Department
Standard Labor Hours Produced Last Quarter
Percentage
1
305
36.3
2
535
63.7
Total
840
100
Capacity Planning Factors (1) Production Plant Next Quarter
Month
Jan
Feb
Mar
Total
Units
40
48
50
138
= 840/120 x 0.363 x 40 Resources Plan in Standard Labors Hours Dept
Jan
Feb
Mar
Total
1
101.67
122.00
127.08
350.75
2
178.33
214.00
222.92
615.25
Total
280.00
336.00
350.00
966.00
Rough-cut Capacity Planning (1)
OPERTATION ITEM NO U V W X Y
10 10 10 20 10 20 10 20
DEPT. NO
WORK CENTER NO.
RUN TIME/UNIT (STANDARD HOURS)
SETUP TIME (STANDARD HOURS)
AVERAGE LOT SIZE
1 1 2 2 2 2 2 2
15 15 35 40 35 40 35 40
1.6 2.4 1.2 0.4 1.1 0.6 0.5 2.1
2 3 1 0.5 2.1 0.6 1.4 0.5
4 6 20 20 8 8 6 6
Rough-cut Capacity Planning (2) Standard hours per unit ITEM
DEPARTMENT
WORK CENTER
STANDARD HOURS PER UNIT
U V W
1 1 2 2 2 2 2 2
15 15 35 40 35 40 35 40
2.100 2.900 1.250 0.425 1.363 0.675 0.733 2.183
X Y
= Run time per unit + (Setup time / Lot size) = 2.1+ (0.5/6) 13
Rough-cut Capacity Planning (3) Bill of Capacity DEPT
PRODUCT U WORK CENTRE
STANDARD LABOR HOURS PER UNIT
1
15
2.100
2
35
2.613
40
1.100
DEPT
PRODUCT V WORK CENTRE
STANDARD LABOR HOURS PER UNIT
1
15
2.900
2
35
1.983
40
2.608
= 1,250 + 0,733
Rough-cut Capacity Planning (4) Master Production Scheduling Week
Capacity Requirements Planning (1) Item W Order quantity: 2 weeks net requirements Week Gross requirements Scheduled receipts Projected available balance Planned order releases
6
Lead time: 2 weeks Safety stock : 0 1 10 30 26
2 10
3 10
4 10
5 11
6 12
7 12
8 13
9 10
10 10
11 10
12 10
13 10
16 15
6
-4 24
-15
-27 23
-39
-52 20
-62
-72 20
-82
-92
-102
Item X Order quantity: 2 weeks net requirements Week Gross requirements Scheduled receipts Projected available balance Planned order releases
10
Lead time: 2 weeks Safety stock : 0 1 4
2 3
3 3
4 3
5 3
6 4
7 4
8 5
9 5
10 6
11 7
12 7
13 8
6
3 6
0
-3 8
-6
-10 10
-14
-19 13
-24
-30 15
-37
-44
-52
Item Y Order quantity: lot for lot Week Gross requirements Scheduled receipts Projected available balance Planned order releases
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