Rough-cut Capacity Planning

The purpose of this procedure is to evaluate the master production schedule for resource requirements and capacity. This is converted into requirements of key resources like machine groups, warehouse space, assembly personnel, and supplier capacity. Comparing load to available capacity indicates the action needed to ensure that the schedule can be carried out.

Basic data such as resource requirements profiles and Rough-cut Capacity Planning (RCCP) groups must be specified and updated to use RCCP.

Load in Rough-cut Capacity Planning is created in a batch run. Resource requirements profile function as keys between planned production and the resources to be loaded. Planned production can be represented in several ways (see diagram).

Available capacity

Rough-cut capacity planning is also used to determine whether planned production can be reasonably completed with the capacity available. The available capacity is measured in terms of rough-cut work centers for machine groups, personnel, or warehouse space. Planned production refers to planned orders, the master production schedule, or sales forecasts. Released manufacturing orders are not included in the rough-cut capacity plan.

The rough-cut capacity plan is created and evaluated after using this process. If resource requirements are greater than available capacity, the plan must be changed and the process repeated.

Relationship

The module interacts with other modules so information is retrieved from forecasting, production and warehouse activity control, and product data management. This module does not update any information to others, but functions to provide a basis for planning long-range resources and production capacity. This way, information is connected indirectly.

A different resource planning basis is selected every time the RCCP calculation is done. The resource planning basis can be a forecast, delivery schedule, forecast according to the consumption method or planned orders. Released manufacturing orders are not included in the calculation since the RCCP horizon is normally so long that the percentage of released production orders is minimal.

Basic data principles

The resources included in the RCCP calculation are selected by the user. For example, bottlenecks can only be specified as resources when these are known. Otherwise, all resources that can limit production must be included in the calculation.

Afterwards, the resource requirements profiles are defined and linked to either the product data or group technology codes. The number of resources needed is specified for each profile. This establishes the connection between planned production and RCCP resources.

RCCP resources are type 4 or 5 work centers. Type 4 work centers are those where the RCCP resource includes one or more type 1 work centers. The capacity of the RCCP resource is the total of the capacity of each detail planning center.

Resource requirements profiles can be created automatically in batches.

Before you start

The process can be started when these prerequisites are met:

Follow these steps

This diagram illustrates the activities in this process.

  1. Calculate projected load

    Projected load is calculated when the resource requirements plan is created. For this, capacity and load are calculated for the RCCP resources specified and connected to products using resource requirements profiles.

    The calculation can be based on either a forecast with or without consumed customer orders, delivery schedules, or planned orders.

    When the resource requirements plan is created, the load panel provides the basis for analysis.

  2. Analyze projected load

    The load can be displayed in various ways for analysis purposes. You can make inquiries regarding underloaded or overloaded work centers, the orders causing the load, and other average estimates of whether the master production schedule is realistic considering the resources available. You can also see how different products load resources. You can carry out the analysis onscreen or in a report.

  3. Fit capacity to projected load

    If any work center is overloaded, the plan must be changed. This is done by:

    • Replanning the order by rescheduling in or out.
    • Moving the order to an alternate work center with available capacity.
    • Modifying the master production schedule.
    • Increasing capacity with extra shifts, investing in new machinery, or subcontracting capacity.

    The changes can be made and evaluated in a simulated environment before being carried out.