Rough Cut Capacity Planning

RCCP

Production Planning and

Control | 1
 Rough Cut Capacity Planning
• RCCP  alat untuk memverifikasi MPS

• Hambatan dalam penerapan Manajemen kapasitas:

– Perlu data yang banyak
– Prosesnya iteratif sehingga memerlukan banyak waktu
– MPS tidak stabil

• Tiga teknik RCCP:

– Capacity planning using overall factors (CPOF)
– Bill of Labor Approach (BOL)
– Resource profile approach (RP)

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 Capacity Planning Capacity
management
techniques
Long range
Resource
Demand Production
requirement
management planning
planning
Referensi : Chapter 12
Fogarthy D.W.,
Rough Blackstone J.H.,
Master Rough Cut
cut
Final assembly
production Capacity
capacity
Hoffmann T.R.,
scheduling Planning Production and
schedule planning
(RCCP)
Inventory
Medium range Management, South
Material Capacity Western Pub. Co,
requirements requirement 1991
planning planning

Short range

Production Input/output
activity control control

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 Master Production Schedule
Produk Lampu LAXX (x1000 units)
Month Forecast Regular Overtime Total Inventory
15
January 22 15 0 15 8
February 8 15 0 15 15
March 10 15 0 15 20
April 10 15 0 15 25
May 20 15 0 15 20
June 14 15 0 15 21
July 8 15 0 15 28
August 8 15 1 16 36
September 12 15 4 19 43
October 15 15 4 19 47
November 30 15 4 19 36
December 40 15 4 19 15
197 180 197

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 Susunan bahan dari Lampu LAXX
(SUPER BILL OF MATERIAL)
Lamps
LAXX

Base Socket
Shades
Assembly Assembly

7” 8” 14B 15W 15C One-way Three-Way

60% 40% 10% 30% 60% 10% 90%

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 Capacity planning using overall factors (CPOF)

• Data yang diperlukan:

– MPS
– Waktu yang diperlukan untuk memproduksi suatu
produk
– Proporsi waktu yang digunakan untuk setiap
sumber daya

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 Techniques 1: CPOF
• Using hostorical proportion
• 0.22 hours per unit product consist of
Work Center Proportion
Assembly 45.50%
Oven 4.50%
Base Forming 22.70%
Plastic Molding 9.10%
Calculate for each work center the
Socket Assembly 18.20% machine loading based on the
proportion !!
 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 0,046 148,5 148,5 148,5 148,5 148,5 148,5 148,5 158,4 188,1 188,1 188,1 188,1 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
 Total capacity requirement = 0.22 x 15000= 3300
 Historical proportion for Lamp Assembly = 0.10 / 0.22 = 0.45
 Lamp Assembly capacity requirement = 0.455 x 3300 = 1501.5, etc.
Oven 0,046 148,5 148,5 148,5 148,5 148,5 148,5 148,5 158,4 188,1 188,1 188,1 188,1 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

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 Techniques 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
 Calculation

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
 Example: RCCP using BOLA for 2 products,
2 months, two 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

c11 c12
cij   aik bkj c11=a11b11+a12b21
WC1 k 1
c12=a11b12+a12b22
WC2 c21 c22 c21=a21b11+a22b21
c22=a21b12+a22b22
RCCP
 Example
. 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
 Lamp Assembly capacity requirement = 0.10 x 15000 = 1500, etc.
 Latihan
• Misalkan ada 2 lampu yang diproduksi yaitu lampu 1 (data awal) dan lampu 2

Januari : : 20.000 lampu

Maret : 10.000 Lampu
April : 22.ooo lampu
Watku proses

• Lamp LAXX2
• Lamp Assembly 0,20 hr
• Oven 0,05 hr
• Base Forming 0,08 hr
• Plastic Molding 0,05 hr
• Socket Assembly 0,08 hr
 Work Center Month Total
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Hours
Lamp Assembly 5.500 1.500 1.500 1.500 1.500 1.500 1.500 1.600 1.900 1.900 1.900 1.900 23.700
Oven 250 150 150 150 150 150 150 160 190 190 190 190 2.070
Base Forming 2.350 750 750 750 750 750 750 800 950 950 950 950 11.450
Plastic Molding 1.300 300 300 300 300 300 300 320 380 380 380 380 4.942
Socket Assembly 2.200 600 600 600 600 600 600 640 760 760 760 760 9.480
Total Capacity
Reqirements 11.600 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
 Lamp Assembly capacity requirement = 0.10 x 15000 = 1500, etc.
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 Techniques 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
 Example: RCCP using RPA:2 products,
3 months horizon, 2 work centers,
3 months 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
 Capacity calculation - RPA
• c11=a110b11+a111b12+a112b13+a210b21+a211b22+a21
2b23
• c12=a110b12+a111b13 +a210b22+a211b23
• c13=a110b13 +a210b23
• c21=a120b11+a121b12+a122b13+a220b21+a221b22+a22
2b23
• 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
 Lamp Assembly = 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.
 Pemilihan metoda RCCP
• Ukuran lot diasumsikan lot-for-lot
• Metoda BOL lebih direkomndasikan dari pada
Metoda CPOF
• Resource profile approach  produk yang
manufacture leadtime lama (contoh : airplane,
machine tools)

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 RCCP Decisions
• Capacity available
Capacity available = time available x utilization x efficiency

• Comparing capacity required to capacity

available
500
Capacity with overtime

400 Capacity without overtime

J F M A M J J A S ON D
Month
Alternatif untuk meningkatkan kapasitas : (1) over time, (2) subcontracting, (3)
alternating routing, (4) tambah tenaga kerja
Jika penambahan kapasitas tidak bisa memenuhi capacity required  Revisi
MPS
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 Soal
Bulan Produksi
Jadwal induk produksi selama tahun 2019 untuk
(unit)
produk Furniture Meja diberikan pada tabel di
sebalah kanan. Januari 1400
Untuk merakit satu meja, 4 buah kaki meja perlu Feb 1200
diproses bubut, papan meja perlu di haluskan
(planed), dan 4 buah lubang pada papan perlu
Maret 1200
proses bor. April 1300
Mei 1500
Total waktu yang diperlukan masing-masing work
Juni 1500
center menyelesaikan komponen untuk 1 unit
meja: Juli 1500
Workcenter Time Agust 1500
Lathe 0.44 jam
Plane 0.25 jam
Sept 1800
Drill 0.10 jam Okt 1800
Nop 1800
Des 1800
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Tersedia 5 (lima) unit mesin bubut (lathe), 2 (dua) unit mesin penghalus (plan), dan
satu buah mesin bor. Waktu kerja bengkel adalah 2 (dua) shift per hari, 5 hari kerja per
minggu, dan 8 jam kerja pershift per hari, satu bulan ada 4 minggu. Jam lembur
ditetapkan maksimum 12 jam per minggu atau 50 jam per bulan. Selama ini rata-rata
tingkat utilisasi ketiga jenis mesin tersebut adalah 95%, sedangkan tingkat efisiensinya
adalah 105% untuk mesin bubut (lathe), 102% untuk mesin planar (plan), dan 112 %
untuk mesin bor.

Hitung kebutuhan kapasitas untuk setiap work center selama tahun 2017 dan
gambarkan load profilenya . (metode BOLA)
Apakah kapasitas yang ada dapat memenuhi jadwal induk produksi yang ditetapkan?

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Terimakasih