Capacity Requirements Planning, Industrial Engineering

Capacity Requirements Planning, Industrial Engineering

1. Capacity Requirement
Planning
Perencanaan & Pengendalian Produksi

2. Pendahuluan
•Proses penentuan jumlah tenaga kerja dan mesin yang dibutuhkan
untuk menyelesaikan kegiatan produksi

•Input untuk menjalankan CRP adalah Planned Order Releases
(dalam MRP)

•CRP menerjemahkan Planned Order Releases menjadi jam kerja di
setiap work center dalam setiap perioda

3. Pendahuluan
.MPS
Cap OK?
Cap OK?
MRP
No
No
Yes
Yes
Vendor ControlDetail Schedule
I/O Control
RCCP
CRP

4. CAPACITY REQUIREMENTS
PLANNING (CRP)
CONTOH :
LEVEL PART QTY/Parent Description
0
1
2
2
100
110
121
122
1
2
6
10
Finished goods
Subassembly
Component I
Component II
ItemOrder
Quantity
On
Hand
On
Order
Due
Date
Lead
Time
Allocated
100
110
121
122
LFL
400
2,400
6,000
0
500
1,500
2,500
250
400
2,400
6,000
7/3
7/10
7/10
7/10
1 week
2
weeks
3
weeks
4
weeks
0
0
0
0

5. Part Work
Center
Setup Time / lot
(minuites
Run Time / piece
(Minutes)
100
110

121


122
1
2
1
3
1
2
2
3
1
3
30
10
15
15
25
15
25
30
75
30
2.5
0.75
0.50
0.25
0.25
0.25
0.75
0.15
0.50
0.35

6. Part Op LS Setup Run Proc Qt/Part Total WC
100 1 200 30 2,500 2,650 1 2,650 1
110 1 400 10 0,750 0,775 2 1,550 2
110 2 400 15 0,500 0,538 2 1,075 1
121 1 2400 15 0,250 0,256 6 1,538 3
121 2 2400 25 0,250 0,260 6 1,563 1
121 3 2400 15 0,250 0,256 6 1,538 2
122 1 6000 25 0,750 0,754 10 7,542 2
122 2 6000 30 0,150 0,155 10 1,550 3
122 3 6000 75 0,500 0,513 10 5,125 1
122 4 6000 30 0,350 0,355 10 3,550 3

7. Work
Center
Available
(minutes)
UtilizationEfficiencyPlanned
Queue
1
2
3
2,400
2,400
2,400
100%
100%
100%
100%
100%
100%
4 days
4 days
4 days
Week
1 2 3 4 5 6 7 8 9 101112
Qty250200250150200300150250200200250200
Rough Cut Capacity Requirements
MPS
Work Center
Master Files
Work Center
Week
1 2 3 4 5 6 7 Average
1 2603 208326031562208331241562 2231
2 2657 212626571594212631891594 2278
3 1659 13281659 996 13281991 996 1422
Total 6920 553669204152553683044152

8. Report RCCP
Meskipun terdapat perioda dengan kondisi KT<KD di beberapa perioda,
RCCP ini menyimpulkan bahwa MPS dapat diterima. Kriteria
penerimaan MPS adalah: Rata-rata kapasitas yang dibutuhkan lebih kecil
dari pada KT (=2400).
Langkah selanjutnya: Teruskan ke MRP

9. Netting ?????? MRP
Item 100, LFL, LT = 1

Period
0 1 2 3 4 5 6 7 8 9 101112
Gross Requirement 250200250150200300150250200200250200
Scheduled Receipts 250
Projected On Hand0 0 0 0 0 0 0 0 0 0 0 0 0
Net Requirement 0200250150200300150250200200250200
Planned Receipts 200250150200300150250200200250200
Planned Release 200250150200300150250200200250200
Item 110, LS = 400, LT =2

Period
0 1 2 3 4 5 6 7 8 9 101112
Gross Requirement 4005003004006003005004004005004000
Scheduled Receipts 400
Projected On Hand500100010010001000 0 0 0 0 0
Net Requirement 0 03003005003004004004005004000
Planned Receipts 400400500400400400400500400
Planned Release 4004005004004004004005004000 0 0

10. Netting ?????? MRP
Item 121, LS = 2400, LT =3

Period
0 1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirement 120012001500120012001200120015001200 0 0 0
Scheduled Receipts 2400
Projected On Hand15003001500 0 1200 0 1200 0 9002100210021002100
Net Requirement 0 0 0 1200 0 1200 0 1500300 0 0 0
Planned Receipts 2400 2400 24002400
Planned Release 0 2400 0 2400 0 24002400 0 0 0 0 0 0
Item 122, LS = 6000, LT =4

Period
0 1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirement 200020002500200020002000200025002000 0 0 0
Scheduled Receipts 6000
Projected On Hand250050045002000 0 40002000 0 35001500150015001500
Net Requirement 0 0 0 0 2000 0 0 2500 0 0 0 0
Planned Receipts 6000 6000
Planned Release 6000 0 0 6000 0 0 0 0 0 0 0 0

11. PLANNED ORDER RELEASES SUMMARY
Period
Part 1 2 3 4 5 6 7 8 9 10 1112
100200 250 150 200 300150 250200 2002502000
110400 400 500 400 400400 400500 4000 0 0
12124000 24000 240024000 0 0 0 0 0
12260000 0 60000 0 0 0 0 0 0 0
Beberapa perioda tidak memproduksi, tapi di beberapa perioda lain
malah jumlah produksi besar. Hal ini terjadi akibat batch policy yang
(barangkali) tidak tepat.

12. Part

1

2

3

4

5

6

7


WC1
100

30

30

30

30

30

30

30

110

0

15

15

15

15

15

15

121

0

25

0

25

0

25

25

122

0

0

75

0

0

75

0



Total

30

70

120

70

45

145

75


WC2
100

0

0

0

0

0

0

0

110

10

10

10

10

10

10

10

121

0

0

15

0

15

0

15

122

25

0

0

25

0

0

25



Total

35

10

25

35

25

10

25


WC3

100

0

0

0

0

0

0

0

110

0

0

0

0

0

0

0

121

15

0

15

0

15

15

0

122

0

30

0

30

30

0

30



Total

15

30

15

30

45

15

30



Set Up Time Matrices
122: WC2 – WC3 – WC1 – WC3

13. Part

1

2

3

4

5

6

7







100

500

625

375

500

750

375

625

110

0

200

200

250

200

200

200

121

0

600

0

600

0

600

600

122

0

0

3000

0

0

3000

0



Total

500

1425

3575

1350

950

4175

1425


WC2

100

0

0

0

0

0

0

0

110

300

300

375

300

300

300

300

121

0

0

600

0

600

0

600

122

4500

0

0

4500

0

0

0



Total

4800

300

975

4800

900

300

900


WC3

100

0

0

0

0

0

0

0

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

WC1
Run Time Matrices
122: WC2 – WC3 – WC1 – WC3

14. WC WEEK
1 2 3 4 5 6 7
I 5301495369514209954320530
II 483531010004835925 3104835
III 615 930 61521301545615 615
Capacity
Requirements of
Planned Releases
Part WCWeekSetup
Time
Run Time
Calculation
Run
Time
Total
Time
100 1 1 30 250 x 2.5 625655
110 2 1 10 400 x 0.75 300310
110 1 2 15 400 x 0.5 200215
121 1 1 25 2400 x 0.25 600625
121 2 2 15 2400 x 0.25 600615
122 1 1 75 6000 x 0.5 30003075
122 3 2 30 6000 x 0.35 21002130
Capacity Required
by Released
Orders

15. WORK
CENTER
WEEK
1 2
I 4355 215
II 310 615
III 0 2130
WC WEEK
1 2 3 4 5 6 7
I 488517103695142099543201495
II514592510004835925310925
III 6153060615213015456152130
Capacity
Requirements
Plan
Released Order Capacity
Requirements Summary

16. CRP profile