Capacity Module Overview

DemandCaster capacity planning module adds the capability to view the impact of open and planned work orders by work center and by location. It is an optional module that may be added to the Basic Forecasting and Inventory Planning Platform or the Sales and Operation Planning Platform.

The capacity module is not a finite scheduling system. Instead, DemandCaster capacity planning module is designed to show user the impact of planned and open orders against the currently defined capacity. Thereafter, users can adjust capacity and reschedule orders as bottlenecks or over scheduled requirements are visualized. 

Here is a list of capabilities:

  • View rough cut capacity planning to identify short and long term capacity shortfalls and bottlenecks with both open and planned work orders.
  • Schedule the number of hours per shift, the number of shifts, and start and end times by work center in either quantity based capacity or time based capacity.
  • Schedule non-working days and shut down periods on a one time or repetitive basis.
  • With the S&OP add-on, create multiple capacity planning scenarios in a sandbox to view impact of the plan prior to approval.
  • In daily requirement planning, update capacity planning and scheduling information on demand or on a scheduled basis throughout the day.
  • Drill in to specific work centers to view work order schedules by day.
  • Reschedule order quantities and due dates to remove over capacity periods.
  • Run work order and scheduling reports on demand.

Prior to describing the navigation of the capacity module, we will review DemandCaster's scheduling methodology.

Scheduling Logic - Time Based

The capacity module requires a routing file and a work center file to operate. To view past due, a shop order progress file is also required.

The shop order file contains an items work order due date and quantity. The routing file contains the items operation steps and set up times and run times by operation. DemandCaster uses this information to schedule a work order as follows:

  1. By default, orders in DemandCaster are back scheduled starting from the orders due date.
  2. The start and end day and time for each operation are based on the items setup time plus the run time multiplied by the total item order quantity.
  3. Time span is the back scheduled by taking the total operation hours required and constraining its schedule based on the available work hours per operation. In the example above, it will take nearly 11 eight hour days to complete the order within the work center. Each day, there is an expectation to complete approximately 8000 units a day.
  4. Each operation is then back scheduled from the last operations start date following the same backward scheduling approach.
  5. By default, the work order is scheduled by routing operation number in numerically ascending order.

Scheduling Logic - Quantity Based

Like the time based capacity approach, the quantity based capacity model requires a routing file and a work center file to operate. To view past due, a shop order progress file is also required. The difference is that the capacity is based on the number of units that can be produced in a day and not how many hours available to produce in a day. Everything else follows the same logic as the time based approach but using units.

Parallel versus Serial Processing

Parallel Processing: The entire capacity is applied to get the job done in the shortest amount of time. For example, if an item has 64 hours of setup and run time and there is 32 hours of capacity a day and there are 8 work hours a day, the item will require 2 calendar days to complete. The entire capacity is applied to get the job done in the shortest amount of time.

Serial Processing: Does not apply the total capacity hours to the job. Instead, it considers one machine or person working on the job. In that case based on the aforementioned example, it will calculate the start date and end date based on the working day hours divided into 64 hours. In this example, it will take 8 days to complete (64/8). However, since the capacity of the cell is 32 hours, the cell is able to accommodate up to 3 more 8 hours jobs in that day before being overloaded.

Bucket Color Coding Logic

When a bucket is Yellow, it means the work-center is scheduled between 75 and 100% of capacity.

Below 75% capacity, the color is green above 100% the color red.

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