SISTEM PRODUKSI

PERENCANAAN KAPASITAS
RCCP

JURUSAN TEKNIK INDUSTRI

UNIVERSITAS BUNG HATTA
2020
Hasil Pembelajaran
Setelah mengikuti perkuliahan ini,
diharapkan mahasiswa:
◦ Memahami konsep dan pengertian kapasitas
serta mampu menghitung kapasitas
◦ Memahami kerangka kerja pengelolaan
kapasitas dalam sistem manufaktur
◦ Mampu menghitung rough cut capacity plan
dari sebuah MPS yang diberikan

Sistem Produksi - TI UBH

Pendahuluan
Jika material merupakan tahapan
perencanaan lebih rinci dari sisi eksternal
setelah pembentukan Jadwal Produksi
Induk, maka perencanaan kapasitas adalah
tahapan perencanaan rinci dari sisi
internal
Memeriksa apakah sumber daya yang
dimiliki (mesin dan orang/tenaga kerja)
mencukupi
 Apakah Kapasitas ?

• jumlah dari keluaran maksimum yang

bisa dihasilkan oleh suatu fasilitas
50 unit per hari;
dalam satu periode waktu tertentu
2 pasien per jam,
• dinyatakan dalam jumlah keluaran per dll.
satuan waktu
 Definisi Kapasitas
Theoretical (or maximum or design) capacity
(TC) is the maximum possible capacity of the
productive system

Demonstrated (or effective) capacity (DC) is the

rate of output that can be expected based on
experience

Actual work time (AWT) is the number of work

hours actually uitlized during a specified period
Theoretical Capacity (synonym: Maximum Capacity, Design
Capacity) merupakan kapasitas maksimum yang mungkin dari
sistem manufakturing yang didasarkan pada asumsi mengenai
adanya kondisi ideal seperti : tiga shift per hari, tujuh hari per
minggu, tidak ada downtime mesin, dan lain-lain.

Demonstrated Capacity (synonym: Actual Capacity, Effective

Capacity) merupakan tingkat output yang dapat diharapkan
berdasarkan pada pengalaman, yang mengukur produksi secara
aktual dari pusat kerja di waktu lalu, yang biasanya diukur
menggunakan angka rata-rata berdasarkan beban kerja normal.

Rated Capacity (synonym: Calculated Capacity, Nominal

Capacity) diukur berdasarkan penyesuaian kapasitas teoritis
dengan faktor produktifitas yang telah ditentukan oleh
demonstrated capacity. Dihitung berdasarkan penggandaan waktu
kerja yang tersedia dengan faktor utilitas dan efisiensi.

Sistem Produksi - TI UBH

 Output Design Capacity
Decided by Designer Effective Capacity
Planned by Planner
C1
C2
C3

Actual Work Time

Performed by
Operator

Time
Big C1-C2 indicates technology management problems

Big C2-C3 indicates operation management problems

Capacity calculation
 The ABC company has a work center made up of 4
milling machines and 4 operators, each operating one 8-
hour shift, 5 days a week. During the past 4 weeks they
have averaged 16 hours of machine downtime per week.
The measured efficiency of the operators is 95%. While
producing a product that required one-fifth hour of
milling, they produced quantities of 600, 620, 610 and
590 in each of the last 4 week.
 Theoretical Capacity = 4x8x3x7=672 hrs/wk  why ?
 Effective Capacity = 4x8x1x5x{(160-16)/160}x.95=123
hrs/wk  ?
 Actual = {(600+620+610+590)/4}x1/5=121 hrs/wk  ?
 Hirarki Perencanaan Kapasitas
Items Production Planning Capacity Planning Resource level
Product lines or Aggregate Resource
families Production Plan Requirements Plan Plants

Individual Master Production Rough-Cut Critical work

products Schedule Capacity Plan centers

Material Capacity All work

Components Requirements Plan Requirements Plan centers

Manufacturing Shop Floor Input/Output Individual

operations Schedule Control machines
 Keberhasilan suatu perencanaan kapasitas di ukur dari besarnya utilisasi
dan efisiensi.
 Utilisasi
Utilisasi adalah mengukur seberapa jauh penggunaan sumber daya.

Jumlah. jam.terpakai
UTILISASI 
jumlah. jam.tersedia

 Efisiensi
Efisiensi adalah mengukur seberapa jauh standar yang dapat tercapai

Jumlah. jam.untuk . produksi

EFISIENSI 
Jumlah. jam.terpakai
 Keputusan dan Umpan Balik
Perencanaan Kapasitas

Lanjutkan ke Purchasing
Terpenuhi
dan PAC

Dari Dalam
Kapasitas yang tersedia
 Lembur,
VS
 Hiring / Lay Off,
Kapasitas yang dibutuhkan Ubah Kapasitas  Make or Buy

Dari Luar
Tidak
Terpenuhi Sub Kontrak

Ubah Rencana Revisi MPS, MRP

Sistem Produksi - TI UBH

Rough Cut Capacity Planning (RCCP)

Mengevaluasi apakah Jadwal Produksi

Induk feasible atau tidak dari sisi
ketersediaan kapasitas
Tiga cara:
◦ Capacity Planning Using Overall Factors (CPOF)
◦ Bill of Labor Approach (BOLA)
◦ Resource Profile Approach (RPA)
 MPS in 1000 units

Example Month Forecast Regular

Production
Over Time
Production
Total
Production
Inventory

January 22 15 0 15 8*
February 8 15 0 15 15
 Plastic moulding March 10 15 0 15 20
company with April 10 15 0 15 25
data on May 20 15 0 15 20
production as June 14 15 0 15 21
follows: July 8 15 0 15 28
 1 shift, 40 hours per
August 8 15 1 16 36
week, max of 10
hours over time, Sept. 12 15 4 19 43
 Desired year end Okt. 15 15 4 19 47
inventory 15,000
Nov. 30 15 4 19 36
units
*) Initial Inventory/desired year Dec. 40 15 4 19 15*
end inventory : 15
Cara 1: CPOF
Menggunakan proporsi waktu secara
historis
0.22 jam per unit produk yang terdiri dari:

Work Center Proportion

Assembly 45.50%
Oven 4.50%
Hitung beban mesin setiap
Base Forming 22.70% work center berdasarkan
Plastic Molding 9.10% proporsi tersebut !!
Socket Assembly 18.20%
 Work Historical Month Total
Center Proportion Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 0.455 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,501.5 1,601.6 1,901.9 1,901.9 1,901.9 1,901.9 19,719.7
Oven 0.0455 148.5 148.5 148.5 148.5 148.5 148.5 148.5 158.4 188.1 188.1 188.1 188.1 1,950.3
Base Forming 0.227 749.1 749.1 749.1 749.1 749.1 749.1 749.1 799.0 948.9 948.9 948.9 948.9 9,838.2
Plastic Molding 0.091 300.3 300.3 300.3 300.3 300.3 300.3 300.3 320.3 380.4 380.4 380.4 380.4 3,943.9
Socket Assembly 0.182 600.6 600.6 600.6 600.6 600.6 600.6 600.6 640.6 760.8 760.8 760.8 760.8 7,887.9
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,300 3,300 3,520 4,180 4,180 4,180 4,180

Lamp LAXX
Lamp Assembly 0.10 hr
Oven 0.01 hr
Base Forming 0.05 hr
Plastic Molding 0.02 hr
Socket Assembly 0.04 hr
0.22 hr

 January
 Kebutuhan kapasitas total = 0.22 x 15000= 3300
 Proporsi historis perakitan lampu= 0.10 / 0.22 = 0.45
 Kebutuhan kapasitas perakitan lampu = 0.455 x 3300 = 1501.5, etc.
Cara 2: BOLA
Bill of labor is a listing by item number of the
amount of labor required by a major labor
category to produce that item or group of part
numbers
Bill of labor:
Work Center Proportion
Assembly 0.10 hour
Oven 0.01 hour
Base Forming 0.05 hour
Plastic Molding 0.02 hour
Socket Assembly 0.04 hour
Total 0.22 hour
 Perhitungan

For n product then n

Capacity Required : a
k 1
b
ik kj i, j

Where:
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
Contoh: RCCP memakai teknik BOLA untuk 2 produk, 2
bulan, 2 work centers
.
P1 P2 M1 M2

WC1 a11 a12 P1 b11 b12

WC2 a21 a22 P2 b21 b22

Bill of Labor MPS

M1 M2 n
cij   aik bkj c11=a11b11+a12b21
WC1 c11 c12
k 1
c12=a11b12+a12b22
WC2 c21 c22 c21=a21b11+a22b21
c22=a21b12+a22b22
RCCP
 Contoh
. P1 P2 M1 M2

WC1 0.3 0.2 P1 100 200

WC2 1.0 0.7 P2 300 400

Bill of Labor MPS

M1 M2
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
 Work Center Month Total
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,600 1,900 1,900 1,900 1,900 19,700
Oven 150 150 150 150 150 150 150 160 190 190 190 190 1,970
Base Forming 750 750 750 750 750 750 750 800 950 950 950 950 9,850
Plastic Molding 300 300 300 300 300 300 300 320 380 380 380 380 3,942
Socket Assembly 600 600 600 600 600 600 600 640 760 760 760 760 7,880
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,300 3,300 3,520 4,180 4,180 4,180 4,180

Lamp LAXX
Lamp Assembly 0.10 hr
Oven 0.01 hr
Base Forming 0.05 hr
Plastic Molding 0.02 hr
Socket Assembly 0.04 hr

 January
 Kebutuhan kapasitas perakitan lampu= 0.10 x 15000 = 1500, etc.
Cara 3: 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
 Contoh: RCCP memakai teknik RPA:2 produk,
3 bulan horison perencanaan, 2 work centers,
3 bulan lead time

RPA Time to due date MPS

2 1 0 M1 M2 M3
a112 a111 a110 P1 b11 b12 b13
P1
P2 a212 a211 a210 P2 b21 b22 b23

Work Center 1
RPA Time to due date RCCP
2 1 0 M1 M2 M3

P1 a122 a121 a120 WC1 c11 c12 c13

P2 a222 a221 a220 WC1 c21 c22 c23

Work Center 2
 Perhitungan Kapasitas- RPA
 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
 Month Total
Work Center Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,600 1,900 1,900 1,900 1,900 19,700
Oven 150 150 150 150 150 150 160 190 190 190 190 0 1,820
Base Forming 750 750 750 750 750 800 950 950 950 950 0 0 8,350
Plastic Molding 300 300 300 300 300 300 320 380 380 380 380 0 3,642
Socket Assembly 600 600 600 600 600 600 640 760 760 760 760 0 7,280
Total Capacity
Reqirements 3,300 3,300 3,300 3,300 3,300 3,350 3,570 3,880 4,180 4,180 3,230 1,900

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

 July
 Perakitan lampu = 0.1 x 15000 (MPS July) = 1500
 Oven = 0.01 x 16000 (MPS August) = 160
 Base forming = 0.05 x 19000 (MPS September) = 950, etc.