Académique Documents
Professionnel Documents
Culture Documents
McGraw-Hill/Irwin
Capacity Planning
Capacity
The upper limit or ceiling on the load that an operating
unit can handle
Capacity needs include
Equipment
Space
Employee skills
5-2
5-3
5-4
5-5
Capacity
Design capacity
Effective capacity
Actual output
5-6
Efficiency
actual output
Efficiency
effective capacity
Utilization
actual output
Utilizatio n
design capacity
Measured as percentages
5-7
90 %
effective capacity 40
actual output
36
Utilizatio n
72 %
design capacity 50
5-8
5-9
Capacity Strategies
Leading
Build capacity in anticipation of future demand increases
Following
Build capacity when demand exceeds current capacity
Tracking
Similar to the following strategy, but adds capacity in relatively
small increments to keep pace with increasing demand
5-10
Strategy Formulation
Strategies are typically based on assumptions
and predictions about:
Long-term demand patterns
Technological change
Competitor behavior
5-11
Capacity Cushion
Capacity Cushion
Extra capacity used to offset demand uncertainty
Capacity cushion = 100% - Utilization
Capacity cushion strategy
Organizations that have greater demand uncertainty
typically have greater capacity cushion
Organizations that have standard products and services
generally have greater capacity cushion
5-12
2.
3.
4.
5.
6.
7.
8.
Monitor results
5-13
5-14
NR
pD
i
i 1
where
N R number of required machines
pi standard processing time for product i
Di demand for product i during the planning horizon
T processing time available during the planning horizon
5-15
5-16
5-17
In-House or Outsource?
Once capacity requirements are determined, the organization
must decide whether to produce a good or service itself or
outsource
Factors to consider:
Available capacity
Expertise
Quality considerations
The nature of demand
Cost
Risks
5-18
Design flexibility
Take stage of life cycle into account
Take a big-picture approach to capacity changes
Prepare to deal with capacity chunks
Attempt to smooth capacity requirements
Identify the optimal operating level
Choose a strategy if expansion is involved
5-19
Minimum
cost
Optimal
Output
Rate
Rate of output
5-20
Economies of Scale
Economies of Scale
If output rate is less than the optimal level, increasing
the output rate results in decreasing average per unit
costs
Reasons for economies of scale:
Fixed costs are spread over a larger number of units
Construction costs increase at a decreasing rate as
facility size increases
Processing costs decrease due to standardization
5-21
Diseconomies of Scale
Diseconomies of Scale
If the output rate is more than the optimal level, increasing the
output rate results in increasing average per unit costs
Reasons for diseconomies of scale
Distribution costs increase due to traffic congestion and
shipping from a centralized facility rather than multiple smaller
facilities
Complexity increases costs
Inflexibility can be an issue
Additional levels of bureaucracy
5-22
Small
plant
Medium
plant
Large
plant
Output rate
5-23
Constraint Management
Constraint
Something that limits the performance of a process or system in
achieving its goals
Categories
Market
Resource
Material
Financial
Knowledge or competency
Policy
5-24
5-25
Evaluating Alternatives
Alternatives should be evaluated from varying
perspectives
Economic
Cost-volume analysis
Financial analysis
Decision theory
Waiting-line analysis
Simulation
Non-economic
Public opinion
5-26
Cost-Volume Analysis
Cost-volume analysis
Focuses on the relationship between cost, revenue,
and volume of output
Fixed Costs (FC)
tend to remain constant regardless of output volume
Total Cost
TC = Q x v
QBEP
FC
Rv
5-28
Cost-Volume Relationships
5-29
5-30
The owner of a company contemplating adding a new line of pies, which will
require leasing new equipment for a monthly payment $6,000. Variable cost s
would be $2.00 per pie and pies would retail for $7.00
a. How many pies must be sold in order to break even?
Q BEP = (FC)/(Rev-VC)
b. What would the profit (loss) be if 1,000 pies are made and sold in a
month?
P=Q(R-v) - FC
c. How many pies must be sold to realize a profit of $4,000?
Q = (P + FC)/ (R v)
d. If 2,000 can be sold and a profit target of $5,000, what price should
be charge per pie?
P=Q(R-v) - FC
5-31
5-32
Financial Analysis
Cash flow
The difference between cash received from sales and
other sources, and cash outflow for labor, material,
overhead, and taxes
Present value
The sum, in current value, of all future cash flow of an
investment proposal
5-33
Financial Analysis
Cash Flow - the difference between cash
received from sales and other sources, and
cash outflow for labor, material, overhead, and
taxes.
Present Value - the sum, in current value, of all
future cash flows of an investment proposal.
5-34