This document discusses capacity planning and aggregate production planning. It describes aggregate planning as intermediate-range planning that typically covers 2 to 18 months and aims to effectively utilize resources to match expected demand. The document outlines various aggregate planning strategies such as altering demand or capacity to match each other. It also discusses techniques for aggregate planning like graphical and mathematical models. Finally, it covers operations scheduling and sequencing, including priority rules.
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Capacity planning is a tedious process for many manufacturing companies. This guide walks readers through a comprehensive, easy-to-follow process toward achieving a best-in-class capacity plan that aligns with S&OP and drives true business impact. Learn more about how River Logic tackles the toughest capacity planning challenges by visiting our website (https://www.riverlogic.com/) or viewing our case studies (https://www.riverlogic.com/resources/)
How to Transform your Capacity Planning Process: Step-by-Step GuideShannon Kearns
Capacity planning is a tedious process for many manufacturing companies. This guide walks readers through a comprehensive, easy-to-follow process toward achieving a best-in-class capacity plan that aligns with S&OP and drives true business impact. Learn more about how River Logic tackles the toughest capacity planning challenges by visiting our website (https://www.riverlogic.com/) or viewing our case studies (https://www.riverlogic.com/resources/)
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2. 5-2 Capacity Planning
1. Concept of Aggregate Production Planning
The term aggregate indicates that the plans are
developed for product lines or product
families, rather than individual products.
Aggregate planning is intermediate-range of
capacity planning that typically covers a time
horizon of 2 to 12 months, although in some
companies it may extend to as much as 18 months.
Aggregate planning is essentially a “big-picture”
approach to planning. Planners usually try to
avoid focusing on individual products or
services unless the organization has only one
major product or service.
3. 5-3 Capacity Planning
Con….
The goal of aggregate planning is to achieve a
production plan that will effectively utilize the
organization’s resources to match expected
demand.
A key objective in business planning is to
coordinate the intermediate plans of various
organization functions, such as
Marketing,
Operations, and
Finance.
4. 5-4 Capacity Planning
Con…..
There are two objectives to aggregate planning:
1. To establish a company-wide game plan for
allocating resources.
The long-standing battle between the sales
and operations functions within a firm.
Since, sales and operations planning is defined as
making intermediate-range decisions to balance
supply and demand, integrating financial and
operations planning
2. To develop an economic strategy for meeting demand.
Matching forecasted demand with available
capacity.
5. 5-5 Capacity Planning
2. Aggregate Planning Strategies (APS)
Proactive
Alter demand to match capacity
Reactive
Alter capacity to match demand
Mixed
Some of each
6. 5-6 Capacity Planning
APS: Demand Options
Demand management is proactive strategy.
1. Influencing demand
Using advertising or promotion to increase
demand in low periods
Using pricing differentials to shift demand
from peak periods to off-peak periods
Attempt to shift demand to slow periods
May not be sufficient to balance demand and
capacity
7. 5-7 Capacity Planning
APS: Demand Options
2. Back ordering (delaying order filling) during high-
demand periods
Requires customers to wait for an order
without loss of goodwill or the order
Orders are taken in one period and deliveries
promised for a later period
The success of this approach depends on
how willing customers are to wait for delivery
Most effective when there are few if any
substitutes for the product or service
Often results in lost sales, disappointed
customers, and perhaps additional paperwork
8. 5-8 Capacity Planning
APS: Demand Options
3. Counter seasonal product and service
mixing/ creating New demand
Develop a product mix of counter
seasonal items
May lead to products or services
outside the company’s areas of
expertise
E.g. Bus transport (trips by schools,
clubs, and senior citizen groups at free
time)
9. 5-9 Capacity Planning
Capacity/Supply Options
Supply management is Reactive strategy.
1. Changing inventory levels
Increase inventory in low demand
periods to meet high demand in the future
Increases costs associated with storage,
insurance, handling, obsolescence, and
capital investment 15% to 40%
Shortages can mean lost sales due to long
lead times and poor customer service
10. 5-10 Capacity Planning
Capacity/Supply Options
2. Varying workforce size by hiring or
layoffs
Match production rate to demand
Training and separation costs for hiring and
laying off workers
New workers may have lower productivity
Laying off workers may lower morale and
productivity
11. 5-11 Capacity Planning
Capacity/Supply Options
3. Varying production rate through overtime or idle
time
Allows constant workforce
May be difficult to meet large increases in demand
Overtime can be costly and may drive down
productivity
Absorbing idle time may be difficult
The use of slack when demand is less than
capacity can be an important consideration.
Some organizations use slack time for training. It
also can give workers time for problem solving and
process improvement, while retraining skilled
workers.
12. 5-12 Capacity Planning
Capacity/Supply Options
4. Subcontracting
Temporary measure during periods of peak
demand
May be costly
Assuring quality and timely delivery may be
difficult
Exposes your customers to a possible
competitor
5. Using part-time workers
Useful for filling unskilled or low skilled
positions, especially in services
13. 5-13 Capacity Planning
General procedure:
1. Determine demand for each period
2. Determine capacities (regular time, overtime,
subcontracting) for each period
3. Identify company or departmental policies that are
pertinent/relevant
4. Determine units costs
5. Develop alternative plans and costs
6. Select the best plan that satisfies objectives. Otherwise
return to step 5.
3. Techniques for Aggregate Planning
14. 5-14 Capacity Planning
Techniques for Aggregate Planning
Techniques for Aggregate Planning:
1. Graphical Techniques/Trial-and-Error Techniques
It consist of developing simple tables or graphs that
enable planners to visually compare projected
demand requirements with existing capacity.
Alternatives are usually evaluated in terms of their
overall costs.
The chief disadvantage of such techniques is that
they do not necessarily result in the optimal
aggregate plan.
15. 5-15 Capacity Planning
2. Mathematical Techniques-linear programming
A number of mathematical techniques have been
developed to handle aggregate planning. They range
from mathematical programming models to heuristic
and computer search models.
Linear Programming (LP). (LP) models are methods
for obtaining optimal solutions to problems involving
the allocation of scarce resources in terms of cost
minimization or profit maximization.
With aggregate planning, the goal is usually to
minimize the sum of costs related to regular labour
time, overtime, subcontracting, carrying inventory, and
costs associated with changing the size of the
workforce.
16. 5-16 Capacity Planning
Simulation Models. A number of simulation
models have been developed for aggregate
planning.
Simulation models: Computerized models that
can be tested under different scenarios to identify
acceptable solutions to problems.
The essence of simulation is the development of
computerized models that can be tested under a
variety of conditions in an attempt to identify
reasonably acceptable (although not always
optimal) solutions to problems.
18. 5-18 Capacity Planning
Scheduling: Establishing the timing of the use of
equipment, facilities and human activities in an
organization
Scheduling is the processes of determining the
starting and completion times to jobs.
Scheduling is a time table for performing
activities, using resources, or allocating facilities.
Effective scheduling can yield
Cost savings
Increases in productivity
1. Operations Scheduling
19. 5-19 Capacity Planning
Scheduling Criteria
1. Minimize completion time
2. Maximize utilization of facilities
3. Minimize work-in-process (WIP)
inventory
4. Minimize customer waiting time
5. Optimize the use of resources so that
production objectives are met
20. 5-20 Capacity Planning
There are two general approaches to scheduling:
Forward and Backward Scheduling
Forward scheduling means scheduling ahead
from a point in time;
Forward scheduling starts as soon as the
requirements are known
Produces a feasible schedule though it may
not meet due dates
Frequently results in buildup of work-in-
process inventory
Due
Date
Now
21. 5-21 Capacity Planning
Forward and Backward Scheduling
Backward scheduling begins with the due
date and schedules the final operation first
Schedule is produced by working backwards
though the processes
Resources may not be available to
accomplish the schedule
Often these approaches are combined to
develop a trade-off between a feasible
schedule and customer due dates
Due
Date
Now
22. 5-22 Capacity Planning
2. Approach that can be used to assign jobs to resources
A. Loading:- assignment of jobs to process centers
When making assignments, managers often seek an
arrangement that will minimize processing and
setup costs, minimize idle time among work
centers, or minimize job completion time,
depending on the situation
Infinite loading: Refers to jobs are assigned to
work centers without regard to the capacity of the
work centers.
Finite loading: Refers to jobs are assigned to work
centers taking into account the work center capacity
and job processing times.
23. 5-23 Capacity Planning
B. Assignment Method/model
A linear programming model for finds optimal
assignment of tasks and resources
Commonly used criteria include costs, profits,
efficiency, and performance
Only one job (or worker) is assigned to one
machine (or project)
Objective is to minimize cost or time
A much simpler approach is to use a procedure
called the Hungarian method to identify the
lowest-cost solution
24. 5-24 Capacity Planning
Assignment Model: Hungarian Method
Method of assigning jobs by a one-for one matching to identify the
lowest-cost solution.
Once the relevant cost information has been acquired and
arranged in tabular form, the basic procedure of the Hungarian
method is as follows:
1. Row reduction: subtract the smallest number in each row from every
number in the row
a. Enter the result in a new table
2. Column reduction: subtract the smallest number in each column from
every number in the column
a. Enter the result in a new table
3. Test whether an optimum assignment can be made
a. Determine the minimum number of lines needed to cross out (cover)
all zeros
b. If the number of lines equals the number of rows, an optimum
assignment is possible. Go to step 6. Else, go to step 4
25. 5-25 Capacity Planning
Hungarian Method (Cont’d)
4. If the number of lines is less than the number of rows, modify the
table:
a. Subtract the smallest number from every uncovered number in
the table
b. Add the smallest uncovered number to the numbers at
intersections of cross-out lines
c. Numbers crossed out but not at intersections of cross-out lines
carry over unchanged to the next table
5. Repeat steps 3 and 4 until an optimal table is obtained
6. Make the assignments
a. Begin with rows or columns with only one zero
b. Match items that have zeros, using only one match for each row
and each column
c. Eliminate both the row and the column after the match
26. 5-26 Capacity Planning
Example: Hungarian Method
Determine the optimum assignment of jobs to
workers for the following data:
Worker
A B C D
Job
1 8 6 2 4
2 6 7 11 10
3 3 5 7 6
4 5 10 12 9
27. 5-27 Capacity Planning
Example: Hungarian Method (contd.)
Worker Row
minimum
A B C D
Job
1 8 6 2 4 2
2 6 7 11 10 6
3 3 5 7 6 3
4 5 10 12 9 5
Worker
A B C D
Job
1 6 4 0 2
2 0 1 5 4
3 0 2 4 3
4 0 5 7 4
Subtract the smallest
number in each row from
every number in the row
28. 5-28 Capacity Planning
Example: Hungarian Method (contd.)
Worker
A B C D
Job
1 6 4 0 2
2 0 1 5 4
3 0 2 4 3
4 0 5 7 4
Column min. 0 1 0 2
Worker
A B C D
Job
1 6 3 0 0
2 0 0 5 2
3 0 1 4 1
4 0 4 7 2
Subtract the smallest
number in each column
from every number in the
column
29. 5-29 Capacity Planning
Example: Hungarian Method (cont’d)
Worker
A B C D
Job
1 6 3 0 0
2 0 0 5 2
3 0 1 4 1
4 0 4 7 2
Determine the minimum
number of lines needed to
cross out (cover) all zeros.
(Try to cross out as many
zeros as possible when
drawing lines
Since only three lines are needed to cross out all zeros and the table
has four rows, this is not the optimum. Note: the smallest uncovered
value is 1
30. 5-30 Capacity Planning
Example: Hungarian Method (cont’d)
Worker
A B C D
Job
1 6 3 0 0
2 0 0 5 2
3 0 1 4 1
4 0 4 7 2
Subtract the smallest uncovered
value from every uncovered
number, and add it to the values
at the intersection of covering
lines.
Worker
A B C D
Job
1 7 3 0 0
2 1 0 5 2
3 0 0 3 0
4 0 3 6 1
31. 5-31 Capacity Planning
Example: Hungarian Method (cont’d)
Worker
A B C D
Job
1 7 3 0 0
2 1 0 5 2
3 0 0 3 0
4 0 3 6 1
Determine the minimum
number of lines needed to
cross out all zeros. (Try to
cross out as many zeros as
possible when drawing lines
Since four lines are needed to cross out
all zeros and the table has four rows,
this an optimal assignment can be made
32. 5-32 Capacity Planning
Example: Hungarian Method (cont’d)
Worker
A B C D
Job
1 7 3 0 0
2 1 0 5 2
3 0 0 3 0
4 0 3 6 1
Make assignments: Start
with rows and columns with
only one zero. Match jobs
with machines that have a
zero cost. Eliminate both the
row and the column after the
match.
33. 5-33 Capacity Planning
3. Sequencing
Sequencing: Determine the order in which
jobs at a work center will be processed.
Workstation: An area where one person
works, usually with special equipment, on a
specialized job.
Priority rules: Simple heuristics/ used to
select the order in which jobs will be
processed.
Job time: Time needed for setup and
processing of a job.
34. 5-34 Capacity Planning
Priority Rules
FCFS - first come, first served
SPT - shortest processing time
EDD - earliest due date
CR - critical ratio: Jobs are processed according to smallest
ratio of time remaining until due date to processing time
remaining.
S/O - slack per operation: Jobs are processed according to
average slack time (time until due date minus remaining
time to process). Compute by dividing slack time by
number of remaining operations, including the current one.
Rush – emergency or preferred customers first.
LPT- Longest Processing Time