Dr.. Ajith Kumar J XLRI Jamshedpur
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PRODUCTION PLANNING AND CONTROL
Ajith Kumar J
Capacity Planning & Management
Dr.. Ajith Kumar J XLRI Jamshedpur
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
Dr.. Ajith Kumar J XLRI Jamshedpur
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
Dr.. Ajith Kumar J XLRI Jamshedpur
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.
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Time/unit‐of‐A = 0.20 hr
Component COp 1, WC 200
Time/unit‐of‐A = 0.60 hr
Component DOp 1, WC 200
Time/unit‐of‐A = 0.10 hr
Component FOp 1, WC 200
Time/unit‐of‐B = 0.25 hr
Component EOp 1, WC 200
Time/unit‐of‐B = 0.20 hr
Component DOp 1, WC 200
Time/unit‐of‐B = 0.10 hr End Item BOp 1, WC 100
Time/unit‐of‐B = 1.30 hr
End item A
End item B
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Dr.. Ajith Kumar J XLRI Jamshedpur
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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
Dr.. Ajith Kumar J XLRI Jamshedpur
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Resource Load Profile
‐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
Dr.. Ajith Kumar J XLRI Jamshedpur
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Resource Load Profile
‐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
Dr.. Ajith Kumar J XLRI Jamshedpur
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Capacity Requirements Planning (CRP)
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.
Dr.. Ajith Kumar J XLRI Jamshedpur
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Capacity Requirements Planning (CRP)
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.
Dr.. Ajith Kumar J XLRI Jamshedpur
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Capacity Requirements Planning (CRP)
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.
Recommended