- Simplifies Resolution of Production Bottlenecks
- Improves Accuracy of Production Schedule
- Enables Better Overtime Scheduling
- Enables Better Utilization of Outside Processing Resources
- Assists in Long-Term Planning of Major Resources Acquisitions
This module provides an effective planning and analysis tool for the management of labor distribution, sub-contracting, and order rescheduling. Capacity planning enables management to level the peaks and valleys in the material plan established by the Master Scheduling and Requirements Planning modules.
The major functions of Capacity Planning consists of a time-phased scheduling system that calculates the detailed load requirements for each work center. Several on-line screens and reports depict the load versus capacity profile for each work center in both detail and graphical summary format.
The Capacity Planning module operates in a simulated environment that is separate from DMACS’ other manufacturing management modules. Capacity Planning loads all of the existing Work In Process routing information for released and planned orders through the Capacity Planning time horizon to separate Capacity Planning tables. This allows management to perform an extensive series of on-line ‘what-if’ simulations without affecting the live production schedule. Once the final capacity plan has been approved by management, the live production plan in Work in Process can be updated via the latest capacity plan.
The major function of capacity planning consists of a time-phased scheduling system that calculates the detail load requirements for each work center. Several on-line screens and reports depict the load versus capacity profile for each work center in both detail and graphical summary format.
Both forward and backward scheduling techniques can be employed when scheduling the start and complete dates for each operation. Also included are inspection time, clerical time, and in-house transit (put a way) time.
Input – Output Control
Capacity Planning can also optionally monitor and control the execution of the CRP plan via its Input-Output Control mechanisms. I-O Control consists of a series of update programs, queries, and reports that provide management with an effective means to balance the input rate of hours with the output rate of hours at each work center.
This helps to stabilize lead times and Work in Process inventory levels throughout the manufacturing facility.
Variable planning intervals can be established to control the summarized CRP and I-O reporting. Intervals can be defined in work days, calendar weeks, months, quarters, or years.
Cumulative deviations are calculated and compared to maximum tolerance levels so that those work centers not conforming to the plan can be immediately reviewed.
Various simulation techniques allow on-line manipulation of the CRP information without affecting the live database. Both on-line and batch net change processing can be utilized for a fast and efficient response to all simulations. Net change processing is available for efficient rescheduling of only those orders affected by work center capacity simulations. A regeneration process initializes, loads, and schedules all CRP information from the Item, Work Center, Standard Routing, Order, and WIP Routing tables.
On-line work center simulations can adjust the available capacity at a work center for an effective date range. In addition, the weekly pattern of work days, the average queue time, the average efficiency, and the average utilization can also be simulated.
On-line order reschedule simulations can be performed for an order’s start date, complete date or required quantity. Similarly, on-line operation reschedule simulations can be performed for an operation’s scheduled start and complete date, work center, priority, etc.
On-line processing automatically forward or backward schedules each affected operation and immediately reveals the effect of the simulation on the load/capacity profile for all affected periods. Tight loading rules and queue reduction factors are additional simulation techniques that can also be employed.
Once management has approved the simulated production plan, all simulated changes to orders and/or operations can be automatically copied to the live Work in Process order and operation tables, respectively. This will keep the live production plan in sync with the simulated schedule.