Transcript Capacity Planning Techniques

Session 13
Capacity Planning Techniques
http://www.pom.edu/mpc/lectures_in_manufacturing_planning.htm
lecture session 14
• Capacity Planning: Role in MPC Systems
• Rough Cut Capacity Planning
– Capacity Bill Technique
– Resource Profiles Technique
• Capacity Requirements Planning
• Capacity Definitions
• Technique Advantages/Limitations
1
Capacity Planning in the MPC System
2
Capacity Bill Example
Sarah Reed. master scheduler at Walnut Hill, has developed a master
production schedule for the XYZ boom box:
Period 1
MPS 450
2
300
3
625
Dept.
Circuit Board
Assembly
Capacity
130
160
4
890
Hours per Unit of End Product
.2
.3
The XYZ is fabricated in several departments, but the circuit board
department and assembly areas are the potential bottlenecks.
Prepare a rough-cut analysis of capacity for the MPS.
3
Problem 4. Sarah Reed
Period:
MPS:
1
450
2
300
3
625
4
890
Capacity Requirements
Capacity
Bill
(.2 hr/unit)
(.3 hr/unit)
Dept
1
Circuit Board 90
Assembly
135
2
60
90
3
4
125 178
187.5 267
Capacity
Available
130 hr/per.
160 hr/per.
Requires: MPS, setup time and run time information from product
routing file.
4
Resource Profile Example
Determine the capacity requirements in all work centers at
Erben Fabricators using the MPS, resource profile, product
structure, and lead time information given below for product Z
and all of its components. (Assume all usages are one and
that a new setup must be made in each period at each work
center.)
Product Z MPS
Part
Z
M
N
O
P
Work center
201
201
202
202
203
1
10
Period
2
3
4
5
20
15
10
15
Product Z resource profile
Setup hours
Run hours/unit
8.0
1.5
5.0
1.0
3.0
2.0
2.0
1.0
1.0
0.5
Planned Lead time
0 periods
1 period
1 period
2 periods
3 periods
5
Resource Profile Solution
MPS
10
20
2
3
38 30.5
20 15
33 23
12 17
4
5
23 30.5
20
33
58 45.5
45 40
43 30.5
33
15
10
15
Period
Dept Item
201 Z
M
202 N
O
203 P
201
202
203
-6
-5
-4
6
6
-3
11
11
-2
-1
12
8.5
15
23
22
6
1
23
25
43
17
8.5
12
8.5
15
45
6
48
60
8.5
Requires: MPS, setup and run time information from the product routing
file, and lead time information.
6
Capacity Requirements Planning
(CRP) Example
The Kuczma Company makes sign mounts
for commercial customers. One
product is the H mount which is made up of a
painted surface on both sides of a wooden H
frame. The H mount is put together in final
assembly. The surfaces are painted in the
paint shop, and frame is made in the frame
shop. Kuczma wants to estimate the H mount
capacity needs for next five periods in final
assembly, the paint shop, and the frame shop.
Operation
Mount assembly
Fabricate H frame
Paint surfaces
Work Center
Final Assembly
Frame Shop
Paint Shop
Setup
Time
2 hours
3 hours
4 hours
Run time
1.0 hours
0.5 hours
0.4 hours
7
Capacity Requirements Planning (CRP) Example (continued)
Item: H frame
Gross requirements
Scheduled Receipts
Projected available balance
Planned order release
Q = 30, LT = 1, SS = 0
Item: Painted Surface
Gross requirements
Scheduled Receipts
Projected available balance
Planned order release
Q = 50, LT = 1, SS = 5
Item: H mount
Gross requirements
Scheduled Receipts
Projected available balance
Planned order release
Q = L4L, LT = 1, SS = 0
10
25
25
2
20
Period
3
4
20 20
5
20
6
0
20
0
0
30
10
30
20
0
20
0
2
40
Period
3
4
40 40
5
40
6
0
5
50
15
50
25
50
35
0
35
0
1
20
2
20
Period
3
4
20 20
5
20
6
20
5
15
0
20
0
20
0
20
0
1
15
15
10
30
1
30
50
45
0
0
20
8
Capacity Requirements Planning (CRP) Example (continued)
H Mount Assy
GR
SR
PAB
POR
H Frame
GR
SR
PAB
POR
Painted Surface GR
SR
PAB
POR
S/U Time* Run Time/unit*
15
20
20
20
20
0
30
30
0
50
50
50
0
2
1
0
3
0.5
0
4
0.4
15
30
50
0
* In hours
9
Capacity Requirements Planning (CRP)
Example (continued)
Capacity Requirements
Dept
H Mount Assy
H Frame
Painted Surface
1
17
28.5
24
Period
2
3
22
22
0
18
24
24
4
22
18
24
5
22
0
0
6
0
0
0
Note: 28.5 = 3 + 0.5(15) + 3 + 0.5(30)
Requires: Planned order and schedule receipt information
from the MRP system, and setup and run times from the
product routing file.
10
Capacity Definitions
• Required capacity: Estimated using capacity planning
techniques
• Rated capacity: Available capacity considering staffing
equipment capabilities
• Demonstrated capacity: Actual (or realized) capacity
based on actual production output
11
Capacity Planning Techniques: Pros and Cons
Pros
Easy to use
Minimal computational
requirements
Consider product mix
Capacity Bills
Cons
Doesn’t consider lead times, inventory
information, or gross-to-netting
Less accurate
Resource Profiles
Doesn’t consider inventory information
or gross-to- netting
Easy to use
Minimal computational
requirements
Considers lead times
Less accurate
Consider product mix
Capacity Requirements Planning
Considers: gross-to-netting,
Requires MRP system, Time-phased
Inventory information,
records, Extensive computational
lead times
requirements
More accurate
12
Considers product mix