5) Rough-Cut Capacity Planning (RCCP)

Departemen Depart emen Teknik Industri FTI-ITB

TI-3122 Pere Pe renc ncan anaa aan n da dan n Pe Peng ngen enda dalilian an Pr Produ oduks ksii

Rough-Cut Capacity Planning

Laborator Laboratorium ium Sistem Sistem Produksi Produksi www.lspitb.org ©2003


Hasilil Pem Has Pembel belaja ajaran ran •

Umum 

•

Mahasi Mahasisw swa a mampu mampu menera menerapka pkan n model model matem matemati atik, k, heur heuris isti tik k dan tekn teknik ik stati statist stik ik untu untuk k meng mengan anal alis isis is dan dan mera meranc ncan ang g suat suatu u sist sistem em pere perenc ncan anaa aan n dan dan peng pengen enda dali lian an produksi

Khusus 

Mema Me maha hami mi kons konsep ep pere perenc ncan anaa aan n kapas kapasit itas as dan dan mamp mampu u menghi menghitun tung g kebutu kebutuhan han kapasit kapasitas as serta serta pengen pengendal dalian ian aktivi aktivitas tas produk produksi si

TI3122-Perencanaan TI3122-Perencanaan dan Pengendalian Produksi Produksi - Minggu 5

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Capacity Planning

Capacity management techniques Long range

Demand management

Production planning

Resource requirement planning

Final assembly scheduling

Master production schedule

Rough cut capacity planning

Medium range Material requirements planning

Capacity requirement planning

Short range Production activity control

Input/output control


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Rough Cut Capacity Planning •

RCCP → alat alat untu untuk k memv memver erif ifik ikas asii MP MPS S

•

Hamb Hambat atan an dalam dalam pener penerap apan an Ma Mana naje jeme men n kapasitas: 





•

Perlu data yang banyak Pros Proses esny nya a iter iterati atiff sehi sehing ngga ga meme memerl rluk ukan an bany banyak ak wakt waktu u MPS tida tidak k stabil stabil

Tiga iga tekn teknik ik RCCP RCCP:: 





Capacity planning using overall factors (CPOF) Bill of Labor Labor Approach Approach (BOL) (BOL) Resource profile approach (RP) TI3122-Perencanaan TI3122-Perencanaan dan Pengendalian Produksi Produksi - Minggu 5

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Master Production Schedule Month January February Marc h A pril May June July A ugus t S ept em ber Oc t ober November Dec em ber

(x1000 units)

Fore ca st

Re gul a r

Ove rti m e

Tota l

22 8 10 10 20 14 8 8 12 15 30 40 197

15 15 15 15 15 15 15 15 15 15 15 15 180

0 0 0 0 0 0 0 1 4 4 4 4

15 15 15 15 15 15 15 16 19 19 19 19 197

I nve ntory 15 8 15 20 25 20 21 28 36 43 47 36 15


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Capacity planning using overall factors (CPOF)

•

Data yang diperlukan: 





MPS Waktu Waktu yang yang diperl diperluka ukan n untuk untuk mempro memproduk duksi si suatu suatu produk Prop Propor orsi si wakt waktu u yang yang digu diguna naka kan n untu untuk k setia setiap p sumb sumber er daya


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CPOF (Contoh) W o rk Cen ter Lamp amp Assembl Assembly y Ov en Ba se se F or ormin g Pla st st ic ic M ol old in in g So ck cket A ss ss em emb ly ly Total Capacity Re q qiire men ts ts

La mp As se mbly Ove n Ba se Forming P la la stic Molding Soc ke ke t Asse mb mbly

•

His to ric al Pro p o rtio n 0.45 0.455 5 0.046 0.227 0.091 0.182

Ja Jan 1,50 1,501. 1.5 5 148.5 749.1 300.3 600.6

Feb 1,50 1,501. 1.5 5 148.5 749.1 300.3 600.6

M ar 1,50 1,501. 1.5 5 148.5 749.1 300.3 600.6

Apr 1,50 1,501. 1.5 5 148.5 749.1 300.3 600.6

M ay 1,50 1,501. 1.5 5 148.5 749.1 300.3 600.6

3,300

3,300

3,300

3,300

3,300

Month Ju n Ju l 1,50 1,501. 1.5 5 1,50 1,501. 1.5 5 148.5 148.5 749.1 749.1 300.3 300.3 600.6 600.6 3,300

3,300

Aug 1,60 1,601. 1.6 6 158.4 799.0 320.3 640.6

Sep 1,90 1,901. 1.9 9 188.1 948.9 380.4 760.8

Oc t 1,90 1,901. 1.9 9 188.1 948.9 380.4 760.8

No v 1,90 1,901. 1.9 9 188.1 948.9 380.4 760.8

De c 1,90 1,901. 1.9 9 188.1 948.9 380.4 760.8

3,520

4,180

4,180

4,180

4,180

To t a l Ho u rs 19,7 19,719 19.7 .7 1,950.3 9,838.2 3,943.9 7,887.9

Lamp LAXX 0.10 hr 0.01 hr 0.05 hr 0.02 hr 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 TI3122-Perencanaan TI3122-Perencanaan dan Pengendalian Produksi Produksi - Minggu 5

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Bill of Labor Approach (BOL) •

Data Data yang yang diperl diperlukan ukan:: sama sama dengan dengan CPOF CPOF

•

Jika Jika ada ada n prod produk, uk, maka maka:: 



n

Kapas Kapasit itas as yang yang dipe diperl rluk ukan an = ∑ k =1 Dimana:

a b ik

kj

untu untuk k selu seluru ruh h i,j i,j

– aik = wak waktu tu yang yang dipe diperl rluk ukan an prod produk uk k di di stas stasiun iun kerj kerja ai – bkj = juml jumlah ah prod produk uk k yang yang aka akan n dipr diprod oduk uksi si pada pada peri period ode ej


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BOL (Contoh) W o rk Cen t er La mp A ss ss em emb ly ly Ov en Bas e Fo rmin g Plas tic M o ld in g So cket A s s emb ly Total Capacity Reqiremen ts ts

Jan 1,500 150 750 300 600

Feb 1,500 150 750 300 600

M ar 1,500 150 750 300 600

A pr 1,500 150 750 300 600

M ay 1,500 150 750 300 600

3,300

3,300

3,300

3,300

3,300

3,300

A ug 1,600 160 800 320 640

Sep 1,900 190 950 380 760

Oct 1,900 190 950 380 760

No v 1,900 190 950 380 760

De c 1,900 190 950 380 760

3,520

4,180

4,180

4,180

4,180

3,300

To t a l Ho u rs 19,700 1, 1,970 9,850 3,942 7,880

Lamp LAXX 0.10 hr 0.01 hr 0.05 hr 0.02 hr 0.04 hr

La mp A sse mbly Ove n Ba se Forming P la la st stic Molding Soc ke ke t Asse mb mbly

•

Month Ju n Ju l 1,500 1,500 150 150 750 750 300 300 600 600

January 

Lamp Assembly capacity requirement = 0.10 x 15000 = 1500

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BOL: Two products, two month, two work centers Bill of labor Product P1 P2 Workcenter W C1

W C2

a1 a11

a12

a2 a21

a22

Master schedule Month M1 M2 Product Product P1

P2

b11

b12

b21

b22

c c c c

11

n

c

ij

=∑ k =1

a b

Bil l of l a bor Produc t P1 P2 Workcenter W C1

W C2

0. 0. 3

0.2

1

0.7

ik

12

kj

21

22

RCCP Month Workcenter W C1

W C2 =

a a =a =a

=

11

b +a b b +a b b +a b b +a b 11

12

21

11

12

12

22

21

11

22

21

21

12

22

22

Ma ste r sche dul e Mont h M1 M2 Product Product P1

P2

100

200

300

40 4 00

M1

M2

c1 c11

c 12

c2 c21

c 22

RCCP Mont h Workcenter W C1

W C2


M1

M2

90

140

310

48 4 80

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Resource profile approach (RP ) •

Metode Meto de perh perhit itun unga gan n miri mirip p BOL BOL + mempertimbangkan lead-time offset

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RPA (Contoh) W o rk Cen t er La mp A ss ss eem mb ly ly Ov e n Ba s e Fo rmin g Pla s tic M o ld in g So cke t A s s emb ly Total Capacity Req ir ireme nt nt s

Feb 1,500 150 750 300 600

M ar 1,500 150 750 300 600

A pr 1,500 150 750 300 600

May 1,500 150 750 300 600

3,300

3,300

3,300

3,300

3,300

Month Ju n Ju l 1,500 1,500 150 160 800 950 300 320 600 640 3,350

3,570

Aug 1,600 190 950 380 760

Sep 1,900 190 950 380 760

Oc t 1,900 190 950 380 760

No v 1,900 190 0 380 760

3,880

4,180

4,180

3,230

Total De c Ho u rs 1,900 19,700 0 1 1,,820 0 8,350 0 3,642 0 7,280 1,900

Months Before Due Date 2 1 0 0 0 0 .1 0 0 .0 1 0 0.05 0 0 0 0 .0 2 0 0 0 .0 4 0

Department Lamp Assembly O ven Base Forming Plastic Molding Socket Assembly

•

Jan 1,500 150 750 300 600

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


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RPA:Two products, two work centers, three month horizon, three month lead time R e s o urc e Pro file

Time to Due Date

M as te r s c he dule

2

1

Month

0

P roduc t

M1

M2

M3

b11

b12

b13

b21

b22

b23

P roduc t p1 p2

R CCP

Month

a 112

a 111

a 110

a 212

a 212

a 210

p1 p2

Work Center

M1

M2

M3

WC1

c 11

c 12

c 13

WC2

c 21

c 22

c 23

Work Work Ce nter 1

2

1

0

p1

a 122

a 121

a 120

p2

a 222

a 221

a 220

c c c c c c

11

11

11

Work Work Ce nter 2

21

22

23

= a110 b11 + a111 b12 + a112 b13 + a 210 b21 + a211 b22 + a 212 b23 = a110 b12 + a111 b13 + a210 b22 + a211 b23 = a110 b13 + a210 b23 =

a b =a b =a b 120

11

120

12

120

13

+ a121 b12 + a112 b13 + a220 b21 + a 221 b22 + a222 b23 + a121 b13 + a 220 b22 + a221 b23 + a 220 b23


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5) Rough-Cut Capacity Planning (RCCP)

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