Perencanaan Kapasitas
2
..pengertian kapasitas…
KAPASITAS DISAIN:
Theoretical Capacity (TC)
keluaran maksimum dalam
KELUARAN kondisi ideal
What-If
Analysis
Material Capacity
Requirement Requirement
Planning Planning
Input/Output
Vendor Production
Control and
Follow -Up Activity
Operations
System Control
Sequencing
A (LT = 1)
C (LT = 2) D (LT = 3)
Minggu:
1 2 3 4 5 6 7 8 9 10
Produk A (LT = 1
minggu)
Gross Requirement 1
Planned Order Release 1
Item C (LT = 2 minggu)
Gross Requirement 1
Planned Order Release 1
Item D (LT = 3 minggu)
Gross Requirement 1
Planned Order Release 1
1.0
0.5
1 2 3 4 5 6 7 8 9 10
Periode
TI3122 Perencanaan & Pengendalian Produksi - 21
Minggu 6
Metode Resource Requirement
Planning ….
• Langkah 4: hitung profil Minggu 6 7 8 9 10
beban untuk setiap
produk pada setiap Produk A 200 200 200
work center dengan Produk B 150 150
melihat JIP
Produk Periode
2 3 4 5 6 7 8 9
lot 1 lot 2 lot 3 lot 4 lot 5
Gr A Gr B Gr A Gr B Gr A
200 150 200 150 200
Lot 3 Lot 5
Waktu standard
50 Lot 2 Lot 4
Lot 1 Lot 1
1 2 3 4 5 6 7 8 9 10
Periode
TI3122 Perencanaan & Pengendalian Produksi - 23
Minggu 6
Metode Resource Requirement
Planning ….
• Langkah 6: simulasikan JIP agar didapat
penggunaan kapasitas yang seimbang
• Contoh:
Produk Periode
2 3 4 5 6 7 8 9
POR
Group A 100 100 100 100 100 100
Group B 75 75 75 75
3 techniques:
• Capacity Planning Using Overall Factors (CPOF)
• Bill of Labor Approach (BOLA)
• Resource Profile Approach (RPA)
J F M A M J J A S O N D
Month
Capacity Required: a
k 1
b
ik kj i, j
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
c11 c12
cij aik bkj c11=a11b11+a12b21
WC1 k 1
c12=a11b12+a12b22
WC2 c21 c22 c21=a21b11+a22b21
c22=a21b12+a22b22
RCCP
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
TI3122 Perencanaan & Pengendalian Produksi - 33
Minggu 6
RCCP Technique
(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
Work Center 1
RPA Time to due date RCCP
2 1 0 M1 M2 M3
Work Center 2
TI3122 Perencanaan & Pengendalian Produksi - 35
Minggu 6
RCCP Technique (RPA):2 products, 3 month
horizon, 2 work centers, 3 month lead time
• 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
MPS Week
1 2 3 4
Whatsits 100 200 250 100
WEEK
1 2 3 4 5 6 7
Quantity 250 200 250 150 200 300 150
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
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
TI3122 Perencanaan & Pengendalian Produksi - 47
Minggu 6
9. Advanced Planning & Control
System
• Enterprise Resource Planning (ERP)
updates MRP II with relational DBMS, GUI &
client/server architecture
• Manufacturing Execution Systems (MES)
links business planning & mgmt control
systems
• Customer-Oriented Manufacturing
Management Systems (COMMS)
unites departments & suppliers around
customer
multi-plant planning, multiple languages &
currencies TI3122 Perencanaan & Pengendalian Produksi - 48
Minggu 6
10. Problems with MRP
• Material requirements plan is first;
capacity is an afterthought
• MRP assumes lead times are fixed and
known
in fact, they are load and schedule
dependent
• MRP tends to lengthen lead times
because they are estimated conservatively
just to be safe