Sec 5- Capacity Management and Production Activity Control Flashcards
Define Capacity Requirements Planning (CRP)
The process of determining in detail the amount of labor and machine resources required to accomplish the tasks of production. Provides a validity check of the priority plan.
Define Capacity Management
The function of establishing, measuring, monitoring, and adjusting limits or levels of capacity in order to execute all manufacturing schedules
What is capacity management called at each of these levels?
1) S&OP
2) master scheduling
3) MRP
4) PAC
1) resource planning
2) RCCP
3) CRP
4) input/output control and operations sequencing
List the 4 steps of the Capacity Planning Process
1) determine available capacity
2) use priority plan to determine amount of capacity required for each time period
3) Sum up the capacities for each time period required for each resource and compare to available capacity for that resource
4) Resolve differences between available and required capacities.
Define Capacity Available
the capability of a system or resource to produce a quantity of output in a particular time period. Can be “rated” or “demonstrated”
How is demonstrated capacity determined?
From historical data
How is rated capacity calculated?
available time X utilization X efficiency
How is available time calculated?
number of machines X hours a day X days a week
How is utilization calculated?
hours actually worked / available hours X 100
How is efficiency calculated?
standard hours of work / hours actually worked X 100
What are the 5 key inputs into the Capacity Requirements Plan (CRP)
Available capacity load data requirements shop calendar lead-time elements
Define Load
the amount of planned work scheduled for and actual work released to a facility, work center, or operation for a specific span of tie. Usually expressed in standard hours of work
How is operation times calculated?
number of pieces x run time per piece + setup time
What sort of data is required to do the Capacity Requirements Plan (CRP)?
open shop orders planned order releases where work is done time needed (standard hours) lead times work center capacity
What is the Manufacturing Calendar?
provides information on the actual number of working days available in each week or month
What are the 5 components of Manufacturing Lead Time?
1) Queue- time spent waiting before an operation begins
2) Setup - time spent getting ready for an operation
3) Run - time spent performing an operation
4) Wait- time spend waiting after operation ends
5) Move - time spent physically moving materials between operations
Define Load Profile
a graphical comparison of each work center’s available capacity and the load established by the planned and released orders for each time period of the plan
What are the 4 objective of the Production Activity Control (PAC)?
1) Execute the MPS and MRP
2) Optimize use of resources
3) Minimize WIP
4) Maintain customer service
What are the 3 functions of the PAC?
1) Plan/Replan - ensure resources are available, schedule start and completion dates, replan if necessary
2) Implement- release shop orders to manufacturing and prepare “shop packet”
3) Control - establish/maintain priority list, monitor control WIP/lead times/queues, track and report production status, report work center performance data
What are the 4 basic scheduling and loading techniques?
Forward scheduling
Backward scheduling
Infinite loading
Finite loading
Define Forward Scheduling
Activities are scheduled form a known start date through a finished date
Define Backward Scheduling
Activities are schedule back from the due date
Define Infinite Loading
Assumes that capacity is infinite at any work center
Define Finite Loading
Assumes there is a definite limit to capacity at any work center
Define Priority Control
Communicating start and completion dates for orders that are to be run at each workstation
Define Critical Ratio (CR)
A dispatching rule that calculates a priority index number by dividing the time to due date remaining by the expected elapsed time to finish the job
Define Input/output Control (I/O)
Technique for capacity control. Monitors both planned/actual inputs and planned/actual outputs.
Define Flow Control
Used in a continuous manufacturing system where materials flow through production at a established rate using fixed routing and dedicated machinery.
