Perencanaan Kapasitas

Hasil Pembelajaran
 Mahasiswa memahami konsep dan pengertian kapasitas
serta mampu menghitung kapasitas
 Mahasiswa memahami kerangka kerja pengelolaan
kapasitas dalam sistem manufaktur
 Mahasiswa mampu menghitung rough cut capacity plan
dari sebuah JIP yang diberikan
 Mahasiswa mampu menghitung capacity requirement
plan dari sebuah MRP

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 Apakah Kapasitas?
Apakah ini yang disebut kapasitas?
• jumlah dari keluaran maksimum
yang bisa dihasilkan oleh suatu
fasilitas dalam satu periode waktu
tertentu
• dinyatakan dalam jumlah keluaran
per satuan waktu

50 unit per hari;

2 pasien per jam,
dll.

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 Definitions on Capacity
Theoretical (or maximum or design)
capacity (TC) is the maximum possible
capacity of the productive system

Demonstrated (or effective) capacity (DC)

is the rate of output that can be expected
based on experience

Actual work time (AWT) is the number of

work hours actually uitlized during a
specified period
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 Design Capacity
Output Decided by Effective Capacity
Designer Planned by
Planner
C1
C2
C3

Actual Work Time

Performed by
Operator

Time
Big C1-C2 indicates technology management problems

Big C2-C3 indicates operation management problems

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 Capacity calculation
 The ABC company has a work center made up of 4
milling machines and 4 operators, each operating one 8-
hour shift, 5 days a week. During the past 4 weeks they
have averaged 16 hours of machine downtime per week.
The measured efficiency of the operators is 95%. While
producing a product that required one-fifth hour of
milling, they produced quantities of 600, 620, 610 and
590 in each of the last 4 week.
 Theoretical Capacity = 4x8x3x7=672 hrs/wk  why ?
 Effective Capacity = 4x8x1x5x{(160-16)/160}x.95=136.8 hrs/wk  ?
 Actual = {(600+620+610+590)/4}x1/5=121 hrs/wk  ?

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 Hierarchy of Capacity Planning
Items Production Planning Capacity Planning Resource level
Product lines Aggregate Resource
or families Production Plan Requirements Plan Plants

Individual Master Production Rough-Cut Critical work

products Schedule Capacity Plan centers

Material Capacity All work

Components Requirements Plan Requirements Plan centers

Manufacturing Shop Floor Input/Output Individual

operations Schedule Control machines

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 Resource Requirement Planning
 Mengubah rencana produksi jangka panjang menjadi
kebutuhan kapasitas
 Dilakukan penyederhanaan dalam bentuk:
4 group produk
4 key work center
4 penggunaan bill of material, route sheets, waktu
standard

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  Untuk melihat cara kerja metode; perhatikan dua buah
produk sbb:

A B

C(1) D(1) C(1) E(1)

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  Process Sheet dari produk (1 work center = 1 orang;1 mesin)
Item Nomor Work Operasi Set up time Run time
Operasi Center (jam/lot) (jam/unit)
A 10 1030 Assembly 0 2,00
B 10 1030 Assembly 0 3,00
C 10 1012 Milling 0,3 0,14
20 1020 Drilling 2,4 0,40
30 1012 Milling 2,7 0,23
40 1018 Grinding 1,0 0,21
D 10 1012 Milling 0,4 0,15
20 1020 Drilling 2,8 0,35
30 1018 Grinding 2,2 0,24
E 10 1012 Milling 0,3 0,18
20 1020 Drilling 2,1 0,39
30 1012 Milling 2,5 0,26
40 1020 Grinding 1,3 0,23

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  Langkah-langkah metode adalah
1. Hitung waktu standard operasi sbb:
Set _ Up _ Time
WSO   Run _ Time
Lot Size
2. Buat Bill of Resource: penjumlahan WSO work
center yang sama
3. Hitung kebutuhan kapasitas dengan mengali-
kan Bill of Resource dgn Rencana Produksi

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  Misalkan Lot Size untuk A, B, C, D, dan E = 15, 10, 25,
20, dan 30
 Untuk contoh maka:
- ambil item C pada work center milling (operasi 10-30)
WSO = (0,3 + 2,7)/25 +(0,14+0,23) = 0,49 jam
- ambil item D pada work center milling (operasi 10)
WSO = 0,4/20 + 0,15 = 0,17 jam
 Secara lengkap adalah sbb:

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 Item Work Center Waktu Standard
Operasi per Unit
C(Q=25) Milling 0,49
Drilling 0,50
Grinding 0,25
D (Q=20) Milling 0,17
Drilling 0,49
Grinding 0,35
E (Q=15) Milling 0,53
Drilling 0,46
Grinding 0,27
A (Q=15) Assembly 2
B (Q=10) Assembly 3

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  Dari hasil tersebut dapat dibuat Bill of Resource sbb:

Work Center Waktu Standard Operasi per Unit

Group Produk A Group Produk B
1012 Milling 0,66 1,02
1020 Drilling 0,99 0,96
1018 Grinding 0,60 0,52
1030 Assembly 2,00 3,00

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  Jika diketahui rencana produksi untuk tahun tertentu
sebesar 3000 untuk produk A dan 2000 untuk produk B
maka:
- kebutuhan kapasitas work center Milling:
3000 x 0,66 + 2000 x 1,02 = 4020 jam
- dengan membandingkan kapasitas yang terse-
dia dapat dievaluasi apakah kapasitas yang di-
perlukan mencukupi atau tidak

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 Rough Cut Capacity Planning
(RCCP)
 Evaluates whether MPS is feasible or not in term of
capacity availability.
 Three techniques:
 Capacity Planning Using Overall Factors (CPOF)
 Bill of Labor Approach (BOLA)
 Resource Profile Approach (RPA)

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 Example Month Forecast
MPS in 1000 units
Regular Over Time Total Inventory
Productio Productio Productio
n n n
 Plastic moulding
company with data on January 22 15 0 15 8*
production as follows: February 8 15 0 15 15
 1 shift, 40 hours per
March 10 15 0 15 20
week, max of 10 hours
over time, April 10 15 0 15 25

 Desired year end May 20 15 0 15 20

inventory 15,000 units June 14 15 0 15 21
July 8 15 0 15 28
August 8 15 1 16 36
Sept. 12 15 4 19 43
Okt. 15 15 4 19 47
Nov. 30 15 4 19 36
*) Initial Inventory/desired
year end inventory : 15 Dec. 40 15 4 19 15*

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 Techniques 1: CPOF
 Using historical proportion
 0.22 hours per unit product consist of
Work Center Proportion
Assembly 45.50%
Oven 4.50%
Base Forming 22.70%
Plastic Molding 9.10%
Socket Assembly 18.20% Calculate for each work center
the machine loading based on
the proportion !!

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 Work Historical Month Total
Center Proportion Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 0.455 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,601.6 1,901.9 1,901.9 1,901.9 1,901.9 19,719.7
Oven 0.046 148.5 148.5 148.5 148.5 148.5 148.5 148.5 158.4 188.1 188.1 188.1 188.1 1,950.3
Base Forming 0.227 749.1 749.1 749.1 749.1 749.1 749.1 749.1 799.0 948.9 948.9 948.9 948.9 9,838.2
Plastic Molding 0.091 300.3 300.3 300.3 300.3 300.3 300.3 300.3 320.3 380.4 380.4 380.4 380.4 3,943.9
Socket Assembly 0.182 600.6 600.6 600.6 600.6 600.6 600.6 600.6 640.6 760.8 760.8 760.8 760.8 7,887.9
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,300 3,300 3,520 4,180 4,180 4,180 4,180

Lamp LAXX
Lamp Assembly 0.10 hr
Oven 0.01 hr
Base Forming 0.05 hr
Plastic Molding 0.02 hr
Socket Assembly 0.04 hr
0.22 hr

 January
 Total capacity requirement = 0.22 x 15000= 3300
 Historical proportion for Lamp Assembly = 0.10 / 0.22 = 0.45
 Lamp Assembly capacity requirement = 0.455 x 3300 = 1501.5, etc.

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 Techniques 2: BOLA
 Bill of labor is a listing by item number of the amount of
labor required by a major labor category to produce that
item or group of part numbers
 Bill of labor:
Work Center Proportion
Assembly 0.10 hour
Oven 0.01 hour
Base Forming 0.05 hour
Plastic Molding 0.02 hour
Socket Assembly 0.04 hour
Total 0.22 hour

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 Calculation

For n product then n

Capacity Required : a
k 1
b
ik kj i, j

Where:
aik denotes for bill of labor amount for Product k in Work Center I
bkj denotes for MPS amount for Product k in period j

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 Example: RCCP using BOLA for 2 products,
2 months, two work centers
.
P1 P2 M1 M2

WC1 a11 a12 P1 b11 b12

WC2 a21 a22 P2 b21 b22

Bill of Labor MPS

M1 M2
n

c11 c12
cij   aik bkj c11=a11b11+a12b21
WC1 k 1
c12=a11b12+a12b22
WC2 c21 c22 c21=a21b11+a22b21
c22=a21b12+a22b22
RCCP

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 Example
. P1 P2 M1 M2

WC1 0.3 0.2 P1 100 200

WC2 1.0 0.7 P2 300 400

Bill of Labor MPS

M1 M2
c11=(0.3)(100)+(0.2)(300)=90
WC1 90 140
c12=(0.3)(200)+(0.2)(400)=140
WC2 310 480 c21=(1.0)(100)+(0.7)(300)=310
c22=(1.0)(200+(0.7)(400)=480
RCCP

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 Work Center Month Total
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,600 1,900 1,900 1,900 1,900 19,700
Oven 150 150 150 150 150 150 150 160 190 190 190 190 1,970
Base Forming 750 750 750 750 750 750 750 800 950 950 950 950 9,850
Plastic Molding 300 300 300 300 300 300 300 320 380 380 380 380 3,942
Socket Assembly 600 600 600 600 600 600 600 640 760 760 760 760 7,880
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,300 3,300 3,520 4,180 4,180 4,180 4,180

Lamp LAXX
Lamp Assembly 0.10 hr
Oven 0.01 hr
Base Forming 0.05 hr
Plastic Molding 0.02 hr
Socket Assembly 0.04 hr

 January
 Lamp Assembly capacity requirement = 0.10 x 15000 = 1500, etc.

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 Techniques 3: RPA
 RPA considers lead time offset (time phases the labor
requirement)
 Input data: MPS and resource profile

Resource Profile:
Months before due date
Department 2 1 0
Lamp Assembly 0 0 0.1
Oven 0 0.01 0
Base Forming 0.05 0 0
Plastic Molding 0 0.02 0
Socket Assembly 0 0.04 0

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 Example: RCCP using RPA:2 products,
3 months horizon, 2 work centers,
3 months lead time

RPA Time to due date MPS

2 1 0 M1 M2 M3
a112 a111 a110 P1 b11 b12 b13
P1
P2 a212 a211 a210 P2 b21 b22 b23

Work Center 1
RPA Time to due date RCCP
2 1 0 M1 M2 M3

P1 a122 a121 a120 WC1 c11 c12 c13

P2 a222 a221 a220 WC1 c21 c22 c23

Work Center 2
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 Capacity calculation - RPA
 c11=a110b11+a111b12+a112b13+a210b21+a211b22+a212b23
 c12=a110b12+a111b13 +a210b22+a211b23
 c13=a110b13 +a210b23
 c21=a120b11+a121b12+a122b13+a220b21+a221b22+a222b23
 c22=a120b12+b121b13 +a220b22+a221b23
 c23= a120b13 a220b23

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 Month Total
Work Center Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,600 1,900 1,900 1,900 1,900 19,700
Oven 150 150 150 150 150 150 160 190 190 190 190 0 1,820
Base Forming 750 750 750 750 750 800 950 950 950 950 0 0 8,350
Plastic Molding 300 300 300 300 300 300 320 380 380 380 380 0 3,642
Socket Assembly 600 600 600 600 600 600 640 760 760 760 760 0 7,280
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,350 3,570 3,880 4,180 4,180 3,230 1,900

Months Before Due Date

Department 2 1 0
Lamp Assembly 0 0 0.1
Oven 0 0.01 0
Base Forming 0.05 0 0
Plastic Molding 0 0.02 0
Socket Assembly 0 0.04 0

 July
 Lamp Assembly = 0.1 x 15000 (MPS July) = 1500
 Oven = 0.01 x 16000 (MPS August) = 160
 Base forming = 0.05 x 19000 (MPS September) = 950, etc.

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 Capacity Requirement Planning
 Dipergunakan untuk memeriksa apakah run MRP bisa
dilakukan dengan kapasitas yang tersedia atau tidak.
 Prinsipnya sama tetapi yang diuji bukan JIP tetapi MRP
atau Planned Order Release.
 Tahap akhir dalam perencanaan sebelum implementasi
produksi dilakukan.

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 Contoh: Pembuatan RCCP dan
CRP

 Misalkan diketahui produk dengan struktur BOM, routing,

dan kapasitas tersedia sbb:

Level Part Qty/Parent Description

0 100 1 Finished Widget
1 110 2 Subassembly
2 121 6 Component A
2 122 10 Component B

Program Studi Teknik Industri - ITB

 Work Center Setup Time/Lot Run Time/piece
Part 100 1 30 min 2.5 min
Part 110 2 10 min 0.75 min
1 15 min 0.5 min
Part 121 3 15 min 0.3 min
1 25 min 0.25 min
2 15 min 0.25 min
Part 122 2 25 min 0.75 min
3 30 min 0.15 min
1 75 min 0.5 min
3 30 min 0.75 min

Work Available Utilization Efficiency Planned

Center Queue
1 2.400 min 100% 100% 4 days
2 2.400 min 100% 100% 4 days
3 2.400 min 100% 100% 4 days

Program Studi Teknik Industri - ITB TMA/Dep. TI-ITB

 Contoh……..
 Diketahui pada 7/1 telah dikeluarkan planned order
release sbb:

Item Order On On Due Lead Allocated

Quantity Hand Order Date Time
100 LFL 0 250 7/3 1 week 0
110 400 500 400 7/10 2 week 0
121 2.400 1.500 2.400 7/10 3 week 0
122 6.000 2.500 6.000 7/10 4 week 0

Program Studi Teknik Industri - ITB

 Contoh:…….
 Diketahui pula JIP untuk produk finished widget
selama 8 minggu ke depan sebagai berikut (dimulai
dari bulan Juli – Agustus) :
WEEK
1 2 3 4 5 6 7 8
Quantity 250 200 250 150 200 300 150 250

Program Studi Teknik Industri - ITB

 Sebelum membuat CRP, buat RCCP terlebih dahulu untuk memvalidasi
JIP yang ada

Program Studi Teknik Industri - ITB

Program Studi Teknik Industri - ITB
Program Studi Teknik Industri - ITB
Program Studi Teknik Industri - ITB
 MRP untuk JIP tersebut sbb:
Item 100 PERIOD
0 1 2 3 4 5 6 7
Gross Req. 250 200 250 150 200 300 150
Sched. Rec 250
On Hand 0 0 0 0 0 0 0 0
Planned Rel. 200 250 150 200 300 150 250

Item 110 PERIOD

0 1 2 3 4 5 6 7
Gross Req. 400 500 300 400 600 300 500
Sched. Rec. 400
On Hand 500 100 0 100 100 0 100 0
Planned Rel. 400 400 500 400 400 400 400

Item 121 PERIOD

0 1 2 3 4 5 6 7
Gross Req. 1200 1200 1500 1200 1200 1200 1200
Sched Rec 2400
On Hand 1500 300 1500 0 1200 0 1200 0
Planned Rel. 2400 0 2400 0 2400 2400 0

Item 122 PERIOD

0 1 2 3 4 5 6 7
Gross Req. 2000 2000 2500 2000 2000 2000 2000
Sched. Rec. 6000
On Hand 2500 500 4500 2000 0 4000 2000 0
Planned Rel. 6000 0 0 6000 0 0 0

Program Studi Teknik Industri - ITB TMA/Dep. TI-ITB

 Ringkasan POR

Part Week
1 2 3 4 5 6 7
100 200 250 150 200 300 150 250
110 400 400 500 400 400 400 400
121 2400 0 2400 0 2400 2400 0
122 6000 0 0 6000 0 0 0

Program Studi Teknik Industri - ITB TMA/Dep. TI-ITB

 Perhitungan kebutuhan kapasitas
SET UP RUN

Part Period
1 2 3 4 5 6 7
WC1 100 30 30 30 30 30 30 30
110 0 15 15 15 15 15 15 Part Period
121 0 25 0 25 0 25 25 1 2 3 4 5 6 7
122 0 0 75 0 0 75 0 WC1 100 500 625 375 500 750 375 625
Total 30 70 120 70 45 145 70 110 0 200 200 250 200 200 200
WC2 100 0 0 0 0 0 0 0 121 0 600 0 600 0 600 600
110 10 10 10 10 10 10 10 122 0 0 3000 0 0 3000 0
121 0 0 15 0 15 0 15 Total 500 1.425 3575 1350 950 4175 1425
122 25 0 0 25 0 0 0 WC2 100 0 0 0 0 0 0 0
Total 35 10 25 35 25 10 25 110 300 300 375 300 300 300 300
WC3 100 0 0 0 0 0 0 0 121 0 0 600 0 600 0 600
110 0 0 0 0 0 0 0 122 4500 0 0 4500 0 0 0
121 15 0 15 0 15 15 0 Total 4800 300 975 4800 900 300 900
122 0 30 0 30 30 0 30 WC3 100 0 0 0 0 0 0 0
Total 15 30 15 30 45 15 30 110 0 0 0 0 0 0 0
121 600 0 600 0 600 600 0
122 0 900 0 2100 900 0 2100
Total 600 900 600 2100 1500 600 2100

Program Studi Teknik Industri - ITB TMA/Dep. TI-ITB

 Kebutuhan kapasitas untuk Planned Order Release
WEEK
1 2 3 4 5 6 7
WC1 530 1495 3695 1420 995 4320 1495
WC2 4835 310 1000 4835 925 310 925
WC3 615 930 615 2130 1545 615 2130

Kebutuhan kapasitas untuk Released Order :

Part WC Week Set Up Run Time Run Total
Time Calculation Time Time
100 1 1 30 250x2.5 625 655
110 2 1 10 400x0.75 300 310
110 1 2 15 400x0.5 200 215
121 1 1 25 2400x0.25 600 625
121 2 2 15 2400x0.25 600 615
122 1 1 75 6000x0.5 3000 3075
122 3 2 30 6000x0.75 4500 4530

Program Studi Teknik Industri - ITB TMA/Dep. TI-ITB

 Ringkasan Kebutuhan kapasitas untuk Released Order:
Work Center Week
1 2
WC1 4355 215
WC2 310 615
WC3 0 4530

Kebutuhan kapasitas keseluruhan:

WEEK
1 2 3 4 5 6 7
WC1 4885 1710 3695 1420 995 4320 1495
WC2 5145 925 1000 4835 925 310 925
WC3 615 5460 615 2130 1545 615 2130

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Program Studi Teknik Industri - ITB Production Planning and Control | 43
 Concluding Remark
 Capacity planning is looking for the availability of
company’s resource
 It is affected by efficiency of resource operation
 Maintenance program; quality management; tools
availability; material management; among others
affecting efficiency
 Operator productivity is also important factor affecting
efficiency

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