Master Data and Orders
The master data of the work centers play a central role in capacity planning. In the work centers, their available capacities and formulas for calculating the capacity requirements of operations are defined. Work centers are assigned to the operations of routings.
Planned orders or production orders are created on the basis of routings. Based on the work center formulas, lead time scheduling takes place for the orders and capacity requirements are created for their operations.
The operations are scheduled infinitely. The non-working times of the work centers are taken into account, but not the capacity requirements of other orders. This can lead to capacity overloads.
As already mentioned, various tools are available for capacity evaluation and capacity leveling. In capacity evaluation, the available capacities of work centers are compared with the capacity requirements of operations. In capacity leveling, operations are scheduled finitely. They are dispatched to periods with free capacity. In this way, the available capacity is guaranteed.
Work Center Data Relevant for Capacity Planning
The figure, Work Center Data Relevant for Capacity Planning, shows work center data that is essential for capacity planning.
The standard values describe the times or activities that can be carried out at a work center. In the example above, the standard values setup time, machine time and labor time are assigned to the work center.
A work center can have several capacity categories. In the example, capacity categories 001 Machine and 002 Labor are assigned.
To each capacity category are assigned formulas for calculating the capacity requirements of operations. For an operation, the capacity requirements for the setup, processing and teardown can be calculated. The figure shows an example of such a formula.
For each capacity category, a daily standard available capacity is defined. The figure describes which elements are included in the calculation of the standard available capacity.
The factory calendar defines the workdays.
You can define time intervals in which the standard available capacity is overridden by specific available capacities, such as shift sequences or downtimes.
You can define several versions of available capacity, such as a standard available capacity, a minimum available capacity, and a maximum available capacity.
A capacity category must be defined as the scheduling basis. The available capacity of this capacity category is taken into account in scheduling.
You must also define formulas for calculating the duration of operations. For an operation, you can calculate the durations for the setup, processing and teardown.
Routing Data Relevant for Capacity Planning
The figure, Routing Data Relevant for Capacity Planning, shows routing data that is essential for capacity planning.
The operations of a routing are assigned work centers and control keys.
For each operation, the standard values are copied from the assigned work center. They are assigned the planned values for production by the work scheduler.
For each operation, furthermore, the interoperation times wait time, queue time and move time can be maintained.
For each operation, the control key defines whether the operation is relevant for scheduling and capacity planning and whether the operation is to be confirmed.