Operations

Management
Capacity Planning

© 2006
© 2006 Prentice
Prentice Hall, Inc. Hall, Inc. S7 – 1
 Capacity

 The throughput, or the number of

units a facility can hold, receive,
store, or produce in a period of time
 Determines fixed costs
 Determines if demand will be
satisfied
 Three time horizons

© 2006 Prentice Hall, Inc. S7 – 2

 Planning Over a Time
Horizon

Long-range Add facilities

planning Add long lead time equipment *
Intermediate- Subcontract Add personnel
range Add equipment Build or use inventory
planning Add shifts

Schedule jobs
Short-range
planning
* Schedule personnel
Allocate machinery

Modify capacity Use capacity

* Limited options exist

© 2006 Prentice Hall, Inc. S7 – 3

 Design and Effective
Capacity
 Design capacity is the maximum
theoretical output of a system
 Normally expressed as a rate
 Effective capacity is the capacity a
firm expects to achieve given current
operating constraints
 Often lower than design capacity

© 2006 Prentice Hall, Inc. S7 – 4

 Utilization and Efficiency
Utilization is the percent of design capacity
achieved

Utilization = Actual Output/Design Capacity

Efficiency is the percent of effective capacity

achieved

Efficiency = Actual Output/Effective Capacity

© 2006 Prentice Hall, Inc. S7 – 5

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

© 2006 Prentice Hall, Inc. S7 – 6

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

© 2006 Prentice Hall, Inc. S7 – 7

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

Utilization = 148,000/201,600 = 73.4%

© 2006 Prentice Hall, Inc. S7 – 8

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

Utilization = 148,000/201,600 = 73.4%

© 2006 Prentice Hall, Inc. S7 – 9

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

Utilization = 148,000/201,600 = 73.4%

Efficiency = 148,000/175,000 = 84.6%

© 2006 Prentice Hall, Inc. S7 – 10

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’

Design capacity = (7 x 3 x 8) x (1,200) = 201,600 rolls

Utilization = 148,000/201,600 = 73.4%

Efficiency = 148,000/175,000 = 84.6%

© 2006 Prentice Hall, Inc. S7 – 11

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, 3 – ‘8 hour shifts’
Efficiency = 84.6%
Efficiency of new line = 75%

Expected Output = (Effective Capacity)(Efficiency)

= (175,000)(.75) = 131,250 rolls

© 2006 Prentice Hall, Inc. S7 – 12

 Bakery Example
Actual production last week = 148,000 rolls
Effective capacity = 175,000 rolls
Design capacity = 1,200 rolls per hour
Bakery operates 7 days/week, three- ‘8 hour shifts’
Efficiency = 84.6%
Efficiency of new line = 75%

Expected Output = (Effective Capacity)(Efficiency)

= (175,000)(.75) = 131,250 rolls

© 2006 Prentice Hall, Inc. S7 – 13

 Managing Demand
 Demand exceeds capacity
 Curtail demand by raising prices,
scheduling longer lead time
 Long term solution is to increase capacity
 Capacity exceeds demand
 Stimulate market
 Product changes
 Adjusting to seasonal demands
 Produce products with complimentary
demand patterns
© 2006 Prentice Hall, Inc. S7 – 14
 Economies and
Diseconomies of Scale
(dollars per room per night)
Average unit cost

25 - Room 75 - Room
Roadside Motel 50 - Room Roadside Motel
Roadside Motel

Economies Diseconomies
of scale of scale
25 50 75
Number of Rooms
Figure S7.2
© 2006 Prentice Hall, Inc. S7 – 15
 Capacity Considerations

 Forecast demand accurately

 Understanding the technology
and capacity increments
 Find the optimal operating level
(volume)
 Build for change

© 2006 Prentice Hall, Inc. S7 – 16

 Approaches to Capacity
Expansion
(a) Leading demand with (b) Leading demand with
incremental expansion one-step expansion
New New
capacity capacity

Demand
Demand

Expected Expected
demand demand

(c) Capacity lags demand with (d) Attempts to have an average

incremental expansion capacity with incremental
New
expansion
capacity New
Demand

Expected Demand capacity Expected

demand demand

Figure S7.4
© 2006 Prentice Hall, Inc. S7 – 17
 Break-Even Analysis

 Technique for evaluating process

and equipment alternatives
 Objective is to find the point in
dollars and units at which cost
equals revenue
 Requires estimation of fixed costs,
variable costs, and revenue

© 2006 Prentice Hall, Inc. S7 – 18

 Break-Even Analysis
 Fixed costs are costs that continue
even if no units are produced
 Depreciation, taxes, debt, mortgage
payments
 Variable costs are costs that vary
with the volume of units produced
 Labor, materials, portion of utilities
 Contribution is the difference between
selling price and variable cost
© 2006 Prentice Hall, Inc. S7 – 19
 Break-Even Analysis
Assumptions
 Costs and revenue are linear
functions
 Generally not the case in the real
world
 We actually know these costs
 Very difficult to accomplish
 There is no time value of money

© 2006 Prentice Hall, Inc. S7 – 20

 Break-Even Analysis
–
Total revenue line
900 –

800 –
Break-even point Total cost line
700 – Total cost = Total revenue
Cost in dollars

600 –

500 –

400 – Variable cost

300 –

200 –

100 – Fixed cost

–
| | | | | | | | | | | |
0 100 200 300 400 500 600 700 800 900 1000 1100
Figure S7.5
Volume (units per period)
© 2006 Prentice Hall, Inc. S7 – 21
 Break-Even Analysis
BEPx = Break-even point in x = Number of units
units produced
BEP$ = Break-even point in TR = Total revenue = Px
dollars F = Fixed costs
P = Price per unit (after V = Variable costs
all discounts) TC = Total costs = F + Vx

Break-even point
occurs when

TR = TC F
or BEPx =
P-V
Px = F + Vx

© 2006 Prentice Hall, Inc. S7 – 22

 Break-Even Analysis
BEPx = Break-even point in x = Number of units
units produced
BEP$ = Break-even point in TR = Total revenue = Px
dollars F = Fixed costs
P = Price per unit (after V = Variable costs
all discounts) TC = Total costs = F + Vx

BEP$ = BEPx P
= F P Profit = TR - TC
P-V = Px - (F + Vx)
= F
= Px - F - Vx
(P - V)/P
F = (P - V)x - F
=
1 - V/P
© 2006 Prentice Hall, Inc. S7 – 23
 Break-Even Example
Fixed costs = $10,000 Material = $.75/unit
Direct labor = $1.50/unit Selling price = $4.00 per unit

F $10,000
BEP$ = =
1 - (V/P) 1 - [(1.50 + .75)/(4.00)]

© 2006 Prentice Hall, Inc. S7 – 24

 Break-Even Example
Fixed costs = $10,000 Material = $.75/unit
Direct labor = $1.50/unit Selling price = $4.00 per unit

F $10,000
BEP$ = =
1 - (V/P) 1 - [(1.50 + .75)/(4.00)]
$10,000
= = $22,857.14
.4375

F $10,000
BEPx = = = 5,714
P-V 4.00 - (1.50 + .75)

© 2006 Prentice Hall, Inc. S7 – 25

 Break-Even Example
Multiproduct Case
F
BEP$ =
∑ 1-
Vi
Pi
x (Wi)

where V = variable cost per unit

P = price per unit
F = fixed costs
W = percent each product is of total dollar sales
i = each product

© 2006 Prentice Hall, Inc. S7 – 26

 Multiproduct Example
Fixed costs = $3,500 per month
Annual Forecasted
Item Price Cost Sales Units
Sandwich $2.95 $1.25 7,000
Soft drink .80 .30 7,000
Baked potato 1.55 .47 5,000
Tea .75 .25 5,000
Salad bar 2.85 1.00 3,000

© 2006 Prentice Hall, Inc. S7 – 27

 Multiproduct Example
Fixed costs = $3,500 per month
Annual Forecasted
Item Price Cost Sales Units
Sandwich $2.95 $1.25 7,000
Soft drink .80 .30 7,000
Baked potato 1.55 .47 Annual 5,000 Weighted
Tea Selling Variable .75 .25Forecasted 5,000
% of Contribution
Item (i) Price (P) Cost (V) (V/P) 1 - (V/P) Sales $ Sales (col 5 x col 7)
Salad bar 2.85 1.00 3,000
Sandwich $2.95 $1.25 .42 .58 $20,650 .446 .259
Soft drink .80 .30 .38 .62 5,600 .121 .075
Baked 1.55 .47 .30 .70 7,750 .167 .117
potato
Tea .75 .25 .33 .67 3,750 .081 .054
Salad bar 2.85 1.00 .35 .65 8,550 .185 .120
$46,300 1.000 .625

© 2006 Prentice Hall, Inc. S7 – 28

 Multiproduct
BEP Example
= $
F

∑ 1 - P x (W )
V i

i
i

Fixed costs = $3,500 per month

$3,500
Annualx Forecasted
12
= = $67,200
Item Price Cost .625
Sales Units
Sandwich $2.95 $1.25 7,000
Soft drink .80 Daily
.30 $67,200
7,000
sales = = $215.38
Baked potato 1.55 312 days
.47 Annual 5,000 Weighted
Tea Selling Variable .75 .25Forecasted 5,000
% of Contribution
Item (i) Price (P) Cost (V) (V/P) 1 - (V/P) Sales $ Sales (col 5 x col 7)
Salad bar 2.85 1.00
.446 x $215.38 3,000
Sandwich $2.95 $1.25 .42 .58 $20,650 = 32.6  .259
.446 33
$2.95 sandwiches
Soft drink .80 .30 .38 .62 5,600 .121 .075
Baked 1.55 .47 .30 .70 7,750 .167 per day
.117
potato
Tea .75 .25 .33 .67 3,750 .081 .054
Salad bar 2.85 1.00 .35 .65 8,550 .185 .120
$46,300 1.000 .625

© 2006 Prentice Hall, Inc. S7 – 29

 Decision Trees and
Capacity Decision
-$14,000
Market favorable (.4)
$100,000

Market unfavorable (.6)

-$90,000
$18,000
Market favorable (.4)
$60,000
Medium plant
Market unfavorable (.6)
-$10,000
$13,000
Market favorable (.4)
$40,000

Market unfavorable (.6)

-$5,000

$0
© 2006 Prentice Hall, Inc. S7 – 30
 Strategy-Driven Investment

 Operations may be responsible

for return-on-investment (ROI)
 Analyzing capacity alternatives
should include capital
investment, variable cost, cash
flows, and net present value

© 2006 Prentice Hall, Inc. S7 – 31

 Net Present Value (NPV)

F
P=
(1 + i)N

where F = future value

P = present value
i = interest rate
N = number of years

© 2006 Prentice Hall, Inc. S7 – 32

 NPV Using Factors
F
P= N = FX
(1 + i)
where X = a factor from Table S7.1
defined as = 1/(1 + i)N and
F = future value

Year 5% 6% 7% … 10%
Portion of
1 .952 .943 .935 .909
Table S7.1 2 .907 .890 .873 .826
3 .864 .840 .816 .751
4 .823 .792 .763 .683
5 .784 .747 .713 .621
© 2006 Prentice Hall, Inc. S7 – 33
 Present Value of an Annuity
An annuity is an investment which
generates uniform equal payments

S = RX
where X = factor from Table S7.2
S = present value of a series of
uniform annual receipts
R = receipts that are received every
year of the life of the investment

© 2006 Prentice Hall, Inc. S7 – 34

 Present Value of an Annuity
Portion of Table S7.2

Year 5% 6% 7% … 10%
1 .952 .943 .935 .909
2 1.859 1.833 1.808 1.736
3 2.723 2.676 2.624 2.487
4 4.329 3.465 3.387 3.170
5 5.076 4.212 4.100 3.791

© 2006 Prentice Hall, Inc. S7 – 35

 Process, Volume, and Variety
Figure 7.1 Volume
Low Repetitive High
Volume Process Volume
High Variety
one or few Process Focus Mass Customization
units per run, projects, job shops (difficult to achieve,
high variety (machine, print, but huge rewards)
(allows carpentry) Dell Computer Co.
customization) Standard Register
Changes in
Modules
modest runs,
standardized Repetitive
modules (autos, motorcycles)
Harley Davidson
Changes in
Attributes Product Focus
(such as grade, (commercial
quality, size, Poor Strategy baked goods,
thickness, etc.) (Both fixed and steel, glass)
long runs only variable costs Nucor Steel
are high)
© 2006 Prentice Hall, Inc. S7 – 36