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Dr.. Ajith Kumar J XLRI Jamshedpur

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PRODUCTION PLANNING AND CONTROL

Ajith Kumar J

Capacity Planning & Management


xLCapacity Planning

2

Aggregate Production Plan

AGGREGATE RESOURCE PLAN

Demand Management

Master Production Schedule

Detailed MRP

ROUGH‐CUT CAPACITY PLANNING

CAPACITY REQUIREMENT PLANNING (CRP)

FINITE LOADING

I/O ANALYSIS Shop floorVendor Systems

Long

rang

eShort ran

geMed

ium ran

ge


xLCapacity Planning Procedures

3

Capacity planning using overall factors (CPOF) Capacity Bills Resource Load Profiles

Capacity Requirements Planning (CRP)

Finite capacity scheduling Input / Output Control

Rough‐cut Capacity Planning

Short Range

Detailed Capacity Planning


xLAn Example

4

A

C D

B

D E 2

F2

Two end‐items A and B made from components C, D, E and F as shown in their respective BOMs below.


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Item Operation WC Lot SizeSetup Time (hr)

SetupTime / unit (hr)

Run Time / unit (hr)

Total Time / unit(hr)

A 1 of 1 100 40 1 0.025 0.025 0.05

B 1 of 1 100 20 1 0.050 1.250 1.30

C 1 of 2 200 40 1 0.025 0.575 0.60

2 of 2 300 1 0.025 0.175 0.20

D 1 of 1 200 60 2 0.033 0.067 0.10

E 1 of 1 200 100 2 0.020 0.080 0.10

F 1 of 1 200 100 2 0.020 0.0425 0.0625

Routing and standard time data

An Example


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Work center – Item Load Matrix

Work Center

END ITEM ONLY COMPONENTS

A B C D E FTime consumed (hr / unit)

100 0.05 1.30

200 0.60 0.10 0.10 0.0625

300 0.20

Consolidate to only end items to form Capacity Bill. E.g. 1 unit of A requires 1 unit of C and 1 unit of D. Hence, 1 unit of A

demands: 0.05 hr from WC100, (0.60+0.10=) 0.70 hr from WC 200 and 0.20 hr from WC300.

An Example


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Capacity Bill

Work Center

END ITEM

A BTotal Time / unit (hr)

Total Time / unit (hr)

100 0.05 1.30

200 0.70 0.55

300 0.20 0

Total time/ unit (hr) 0.95 1.85

For 1 unit of each end‐item, the load exerted on each work center.

An Example


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Operation Setback Chart

Period XPeriod X–1Period X–2

End Item AOp 1, WC 100

Time/unit‐of‐A = 0.05 hr

Component COp 2, WC 300


Component COp 1, WC 200


Component DOp 1, WC 200


Component FOp 1, WC 200

Time/unit‐of‐B = 0.25 hr

Component EOp 1, WC 200


Component DOp 1, WC 200

Time/unit‐of‐B = 0.10 hr End Item BOp 1, WC 100


End item A

End item B


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Loads on WC in Period X

WCfrom 1 unit of the POR

of A in period

X X+1 X+2

WC100 0.05

WC200 0.1 0.6

WC300 0.2

WCfrom 1 unit of the POR

of B in period

X X+1 X+2

WC100 1.3

WC200 0.3 0.25

WC300

0 hr from each unit of POR of A in period X 0.1 hr from each unit of POR of A in period X+1 0.6 hr from each unit of POR of A in Period X+2 0 hr from each unit of POR of B in period X 0.3 hr from each unit of POR of B in period X+1 0.25 hr from each unit of POR of B in period X+2

For example, the load on WC 200 in period X arises from all of these:‐

Time‐phased Capacity Bill


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Resource Load Profile

X X+1 X+2

WC100 0.05

WC200 0.1 0.6

WC300 0.2

‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

WC100 0 0 1.65 1.65 1.65 2 2 2 1.5 1.5 1.5 1.85 1.85 1.85 1.85

WC200 19.8 23.1 23.1 27.3 28 28 22 21 21 25.2 25.9 25.9 25.9 3.7 0

WC300 0 6.6 6.6 6.6 8 8 8 6 6 6 7.4 7.4 7.4 7.4 0

MPS for A and B (indicates qty to be completed by end of time period)

Period‐wise loads on the different Work Centers placed by the entire MPS of A

(40*0 + 40*0.1 + 30*0.6)(37*0.05 + 37*0 + 37*0)

‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

A 33 33 33 40 40 40 30 30 30 37 37 37 37

B 17 17 17 13 13 13 25 25 25 27 27 27 27

Take MPS to be the same as POR here


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‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

A 33 33 33 40 40 40 30 30 30 37 37 37 37

B 17 17 17 13 13 13 25 25 25 27 27 27 27

X X+1 X+2

WC100 1.3

WC200 0.3 0.25

WC300

‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

WC100 0 0 22.1 22.1 22.1 16.9 16.9 16.9 32.5 32.5 32.5 35.1 35.1 35.1 35.1

WC200 4.25 9.35 9.35 8.35 7.15 7.15 10.15 13.75 13.75 14.25 14.85 14.85 14.85 8.1 0

WC300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MPS for A and B (indicates qty to be completed by end of time period)

Period‐wise loads on the different Work Centers placed by the entire MPS of B

(17*1.3 + 13*0 + 13*0)(27*0 + 27*0.3 + 27*0.25)

Take MPS to be the same as POR here


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‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

WC100 0 0 23.75 23.75 23.75 18.9 18.9 18.9 34 34 34 36.95 36.95 36.95 36.95

WC200 24.05 32.45 32.45 35.65 35.15 35.15 32.15 34.75 34.75 39.45 40.75 40.75 40.75 11.8 0

WC300 0 6.6 6.6 6.6 8 8 8 6 6 6 7.4 7.4 7.4 7.4 0

Period‐wise loads on the different Work Centers – total of A & B

‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

WC100 0 0 1.65 1.65 1.65 2 2 2 1.5 1.5 1.5 1.85 1.85 1.85 1.85

WC200 19.8 23.1 23.1 27.3 28 28 22 21 21 25.2 25.9 25.9 25.9 3.7 0

WC300 0 6.6 6.6 6.6 8 8 8 6 6 6 7.4 7.4 7.4 7.4 0

Period‐wise loads on the different Work Centers placed by the entire MPS of A

‐1 0 1 2 3 4 5 6 7 8 9 10 11 12 13

WC100 0 0 22.1 22.1 22.1 16.9 16.9 16.9 32.5 32.5 32.5 35.1 35.1 35.1 35.1

WC200 4.25 9.35 9.35 8.35 7.15 7.15 10.15 13.75 13.75 14.25 14.85 14.85 14.85 8.1 0

WC300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Period‐wise loads on the different Work Centers placed by the entire MPS of B


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Current on‐hand inventory for items C, D and E are 260, 200, 100 respectively. There is an open shop order for 110 units of C scheduled to arrive in Week 2.

1 2 3 4 5 6

A 50 75 25 50 200 0

B 75 0 125 100 150

A production facility produces two final products, A and B (see MPS). The MPS indicates quantity to be completed by the end of the respective time periods.


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Period XPeriod X–1Period X–2

Component COp 1, WC 200Time/unit = 0.10 hr

Component DOp 1, WC 200Time/unit = 0.20 hr

Component COp 2, WC 300Time/unit = 0.15 hr End Item A

Op 1, WC 100

Time/unit = 0.05 hr

Component EOp 1, WC 300

Time/unit = 0.15 hr

Component Fpurchased

Determine capacity requirements in all WCs.

The operations setback chart for A is shown below. Item B is similar but requires two Cs.


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Takes into account the MRP records of the components.o Scheduled receipts (open shop orders).o On‐hand inventory.

o Net requirements.

Planned order release is used to compute the loads.

o Safety stock.o Lot size.

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