1. CAPACITY PLANNING Prof. Dr. Orhan Torkul Res. Assist. M. Raşit Cesur

2. Capacity Planning Manufacturing planning and control system includes two main activities, material and capacity planning and control. These two main activities shoulb be in a harmony while determining market needs for utulizing manufacturing planning and control system maximum. A critical activitiy that parallels developing material plans is developing capacity plans.

3. Capacity Planning Process Resource planning Rough-cut capacity planning Production planning Demand management Master production scheduling Long range

4. Capacity Planning Process Capacity requirements planning Finite loading Input/Output Analysis Detailed material planning Shop – floor systems Vendor systems Medium range Short Range

5. Capacity Planning Process Resource planning is the decision of using capacity, covers largest planning horizon. Resource planning consists of monthly, 3 months period or yearly data transformation from sales and operations plans for resources like facility layout, gross workforce, and machinery hours. MPS is basic information resource for capacity planning. Finite loading, is controlling material folw for optimum capacity usage. Input output analysis: Monitoring capaciy when capacity plans are performed.

6. Basic Concepts Work centre: Place where product and service is produced. Operation : Actions which are performed for production of product or service. Route: The list in which operations are recorded by sequence for producing product. Processing time: The time that production operations take. Setup time: The time of setting work centre up which isn’t related to amounth of product.

7. Coffee Table Production Process Chipboard sheets are cutted into smaller pieces that are needed for production of cıffee table. This is called cutting process. Cutted chipboards which are used for production of top plate are covered with PVC on four side. This process is called edge banding. Finally, all pieces are drilled for assembly in derilling operation and assembled together in assembly operation.

8. Furniture Production Videos

9. BOM of Coffee Table All processing time defined below, are for production of 1 unit. 4 legs and 4 curtains are needed for production of 1 coffee table. ParentRouteChildAmounth COFFEE TABLE Assembly (60 min) TOP PLATE1 LEG4 SKIRT4 TOP PLATE Cutting (40 min), Edge Banding (80 min), Drilling (10 min) CHIPBOARD0.64 m 2 PVC3.2 m LEGCutting (10 min), Drilling(10 min) WOODDEN BAR1 SCREW2 SKIRT Cutting (10 min), Edge Banding (10 min),Drilling(10 min) CHIPBOARD0.06 m 2 PVC0.6 m

10. Capacity Planning and Control Techniques Capacity planninh with general factors; Data is suplied from MPS. Generally old and well known data and standart data are used. Capacity of facility and machine capacities are calculated. Calculations are detailed by calculating capacities of work centers.. There isn’t large amounth of data entry needed. Easy to calculate. It’s feasible when products are similar.

11. Example of General Factors All components of coffee table are processed in cutting 120 mins (40+4x10+4x10), edge banding 120 mins, drilling 90 mins and assembly 60 mins. Planned products after MRP run; ÜrünHafta 1Hafta 2Hafta 3Hafta 4Hafta 5Hafta 6Hafta 7Hafta 8 COFFEE TABLE818131817192225 Work CenterProcessing Time(hours) Cutting1636263634384450 Edge Banding1636263634384450 Drilling122719.52725.527.53337.5 Assembly818121817192225

12. Capacity Planning and Control Techniques Capacity records; Capacities of workcenters with the detail of products in MPS are calculated by this technique. It requires more data then general factors. Material records and detailed routes are needed. All operation times are needed for every machine performing the operation. This metod enables for more detailed capacity plannig for every workcenters.

13. Example of Capacity Record Capacity is calculated for every single piece of product. ProductWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8 COFFEE TABLE818131817192225 Work CenterProcessing Time(hour) Assembly818131817192225

14. Example of Capacity Record ProductWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8 TOP PLATE818131817192225 Work CenterProcessing Time(hours) Cutting (40 min)5.33128.671211.3312.6714.6716.67 Edge Banding (80 min) 10.672417.332422.6725.3329.3333.33 Drilling (10 min)1.3332.1732.833.173.674.17

15. Example of Capacity Record ProductWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8 LEG818131817192225 Work CenterProcessing Time(hour) Cutting (10 min)1.3332.1732.833.173.674.17 Drilling (10 min)1.3332.1732.833.173.674.17

16. Example of Capacity Record ProductWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8 SKIRT818131817192225 Work CenterProcessing Time(hour) Cutting (10 min)1.3332.1732.833.173.674.17 Edge Banding (10 min) 1.3332.1732.833.173.674.17 Drilling (10 min)1.3332.1732.833.173.674.17

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