Aggregate Planning and RCCP


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Aggregate Planning and RCCP

  2. 2. Aggregate Production Plan  Aggregate production plans or production planning is to determine the level or rate of production plants in the aggregate stated that plans are made for all products that use the same source, without elaborated in each of the different products
  3. 3. Aggregate Production Plan Objective  Set production strategy  Producing appropriate demand  Determine resource requirements  The first step for all production activities
  4. 4. Aggregate Planning Strategies  Chase Strategies  Match demand during the planning horizon by either  Vary workforce or vary output rate  Level Strategies  Maintain a constant workforce level or constant output rate during the planning horizon  Constant workforce or constant output rate  Mixed Strategies  Combined several strategies
  5. 5. Master Production Schedule (MPS)  Master production schedule (MPS) is a statement of the final product to be produced in the form of number and time
  6. 6. Four Importance Function of the MPS  Schedule the production and purchase of materials for the product (item).  Make data input material requirements planning system. MPS are translated using the BOM to determine the amount of material components and assembly needs so that MPS can be met.  As the basis for determining resource requirements, such as labor, machine hours, or energy through a rough calculation of capacity planning.  As the basis for determining product delivery promises to customers.
  7. 7. The effects if not properly structured MPS: 1. Production does not match request 2. Not optimal capacity utilization 3. Delay in delivery time 4. Load uneven production
  8. 8. Disaggregation  Disaggregation process is a process of equalization of aggregate units into units of end item based on the conversion factor, the results of this disaggregation of a master production schedule / MPS  This disaggregation process objective is to develop the master production schedule (MPS) after the aggregate production schedules know.  Disaggregation technique:  Precentage Techniques  Bitran and Hax Methods
  9. 9. RCCP (Rough Cut Capacity Planning)  rough-cut capacity planning (RCCP) - used to check feasibility of MPS. Converts MPS from production needed to capacity required, then compares it to capacity available.
  10. 10. Four steps RCCP 1. Obtain information about the production plans of the JIP 2. Obtain structural information and the product lead time (Lead Time) 3. Determining the Bill of Resources 4. Calculate the specific resource requirements and create reports RCCP
  11. 11. RCCP Techniques 1. Bill Of Labour Approach (BOLA) 2. Capacity Planning Using Overall Factor (CPOF)
  12. 12. Bill of Labour Approach (BOLA)  BOLA - using standard time detailed data for each unit of product. Capacity Requirement = Total production x operation time
  13. 13. BOLA: Two products, two month, two week MPS Bill of Labour RCCP
  14. 14. CPOF (Capacity Planning Using Overall Factor)  There are three inputs to calculating RCCP using CPOF methods: 1. MPS 2. Total time required to produce a product 3. The proportion of time the use of source
  15. 15. CPOF (Capacity Planning Using Overall Factor)  MPS  Bill of Resources WC Time 1 0,1 2 0,8 3 0,22 • The proportion of time the use of source : 0,1/1,12 = 0,089
  16. 16. CPOF (Capacity Planning Using Overall Factor)  RCCP report
  17. 17. Decisions taken based on RCCP 1. Calculating Capacity – involves the relationship below: Capacity = Available time X Utilization X Efficiency where: Available time - total production time available for production purposes. Utilization - is the proportion that measures how intensely a resource is being used. Efficiency - is the proportion that measures how closely predetermined standards such as productivity index are achieved.
  18. 18. Decisions taken based on RCCP (Cont.) 2. Comparing the available capacity with the required capacity. When capacity is not enough, some of the basic choices available to increase capacity: a. Overtime b. Subcontracting c. Alternate Routing d. Hiring and Layoff e. MPS Revision