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08mfg62s-CAP

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08mfg62s-CAP

    2010-10-24 23:45:00

    Insert Tab Here Unit 8Capacity Planning

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Unit 8Capacity Planning

    UNIT INTRODUCTION .............................................................................................. 1

    OBJECTIVES ....................................................................................................... 1 CAPACITY PLANNING .............................................................................................. 3

    MRP II AND CAPACITY PLANNING INTEGRATION ........................................... 3 ROUGH CUT CAPACITY PLANNING ..................................................................... 21

    WORK CENTER LOAD INQUIRY .................................................................... 28

    WORK CENTER LOAD REPORT .................................................................... 28 DETAIL CAPACITY PLANNING .............................................................................. 30 SCHEDULING METHODOLOGIES ......................................................................... 32

    WORK CENTER LOAD INQUIRY .................................................................... 39

    RESOURCE REQUIREMENTS REPORT ........................................................ 39

    GROUP TECHNOLOGY REPORT ................................................................... 39 DETAIL CAPACITY PLAN ADJUSTMENTS ............................................................ 40

    OPERATION OVERLAPPING ............................................................................ 41

    ALTERNATE MATERIAL METHOD ................................................................. 42

    ALTERNATE ROUTING METHOD ................................................................... 42 INPUT/OUTPUT CONTROL .................................................................................... 43

    INPUT/OUTPUT CONTROL REPORT ............................................................. 49

    WORK CENTER LOAD INQUIRY .................................................................... 49 CONTINUOUS PLANNING PROCESS ................................................................... 50 FINITE FORWARD SCHEDULING ......................................................................... 53 CAPACITY PLANNING REVIEW............................................................................. 55

     Table of Contents 8-i

List of Tables

    TABLE 8 - 1. CAPACITY MANAGEMENT ................................................................ 9 TABLE 8 - 2. CONSTRAINING RESOURCE .......................................................... 19 TABLE 8 - 3. ROUGH CUT VERSUS DETAIL CAPACITY PLANNING.................. 20

    TABLE 8 - 4. CAPACITY EVALUATION LOGIC ..................................................... 27 TABLE 8 - 5. INPUT/OUTPUT CONTROL ............................................................. 47 TABLE 8 - 6. INPUT/OUTPUT ................................................................................ 48 TABLE 8 - 7 MANUFACTURING SCHEDULE ........................................................ 52

     Table of Contents 8-iii

Unit Introduction

    This unit covers Capacity Planning and Finite Forward Scheduling.

    Rough Cut and Detail Capacity Planning are both generated through BPCS Capacity Planning (CAP) product.

    Finite Forward Scheduling is a key planning tool that builds a schedule combining both priority planning and finite capacity planning techniques. Using simulation, short term executable schedules are created based on current shop conditions.

    Objectives

    At the end of this unit you will be able to:

     Identify critical work centers in your organization.

     Generate a Rough Cut Capacity Plan.

     Generate a Detail Capacity Plan.

     Identify the role of Finite Forward Scheduling.

     Capacity Planning 8-1

Capacity Planning

    Capacity Planning (CAP) allows the generation of both Rough Cut Capacity plans and Detail Capacity plans.

    Rough Cut Capacity Planning is run during the Master Production Scheduling (MPS) stage for critical work centers only. This allows solving potential problems during early planning. Detail Capacity Planning is run during the Material Requirements Planning (MRP) phase for all work centers. This checks all load against capacity, and includes current production. MRP II and Capacity Planning Integration

    The following figure shows Manufacturing Resource Planning (MRP II) highlighting Capacity Planning (CAP). Notice there are two types of planning, rough cut and detail, both within the Operations Management Planning phase.

    Business Planning

    AccountsSales PlanningSales PlanningOrderPlanningOrderForecastingReceivableForecastingProcessingProcessingBillsItemMaster

    Production PlanningBill ofIResourcesRough CutMasterNCapacityProductionVGeneralPlanningSchedulingBills ofLedgerEMaterial

    N(Configurable)MaterialCapacityDepartmentsRequirementsRequirementsTPlanningPlanningOWorkCentersRFinite ForwardYSchedulingRoutingsAccountsPayableProductionCostActivityPurchasingStandardsControlCostActualsAccountingPerformanceMeasurement

    Figure 8- 1 MRPII and Capacity Planning Integration

     Capacity Planning 8-3

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