MPO KAPASITAS PABRIK

Summary

The lecture focuses on production and operations management, specifically capacity planning in manufacturing. It explains different types of capacity, such as design capacity, rated capacity, standard capacity, and actual capacity, and their significance in production schedules. The session also discusses the importance of understanding output units and time in capacity planning, the role of resources like machines, labor, and raw materials, and the relationship between capacity and production demand. It highlights economic scale factors that influence production costs and efficiency. Practical examples are provided, emphasizing the calculation and optimization of production capacity.

Takeaways

• 😀 Capacity refers to the maximum output that can be produced in a given time, directly impacting production planning and scheduling.
• 😀 Design capacity is the theoretical maximum output of a factory based on its initial design, often used as a baseline for production goals.
• 😀 Effective capacity accounts for real-world factors like machine downtime and worker inefficiency, giving a more realistic production estimate.
• 😀 Actual operating capacity represents the actual output achieved during a specific time period, influenced by operational conditions.
• 😀 Rated capacity is higher than design capacity and assumes periodic maintenance and machine upgrades to improve production efficiency.
• 😀 The relationship between production capacity and production schedule is crucial for determining resource needs, output quantity, and deadlines.
• 😀 Short-term, medium-term, and long-term capacity planning all play a role in managing production output over different time frames, each requiring different levels of decision-making.
• 😀 Economic scale refers to cost efficiencies gained by increasing production volume, which results in lower costs per unit produced.
• 😀 Diseconomies of scale occur when increasing production scale leads to inefficiencies and higher per-unit production costs.
• 😀 In capacity planning, it's important to determine the correct unit of output (e.g., kg, ton, piece) and the appropriate time unit (e.g., hours, days, months) to measure production efficiency.
• 😀 To calculate required machine time, multiply the number of machines, operating hours, shifts, and efficiency rate, then adjust for setup time and other factors to ensure accurate capacity planning.

Q & A

What is the concept of production capacity in manufacturing?

Production capacity refers to the maximum output a factory can produce within a specific time frame. It is determined by factors such as machine availability, labor, and raw materials.

How is production capacity related to production scheduling?

Production capacity is directly tied to production scheduling because it determines the amount and type of output that can be produced in a specific time period. A well-planned schedule aligns with the factory’s capacity to avoid under- or over-production.

What are the different types of capacity, and how do they differ?

There are several types of capacity: Design capacity (maximum output when the factory is designed), Rated capacity (theoretical maximum with periodic maintenance), Standard capacity (target output for operational goals), Actual/Operating capacity (real output achieved), and Practical capacity (output achieved through optimization like overtime).

How is rated capacity different from design capacity?

Rated capacity is typically higher than design capacity because it accounts for improvements and repairs made to the machines or processes, whereas design capacity reflects the initial maximum output when the factory is first built.

What role does efficiency play in calculating capacity?

Efficiency is crucial in determining actual capacity. The more efficient the system, the higher the actual output will be relative to the theoretical or rated capacity. This is typically factored into calculations as a percentage.

How are time periods categorized in capacity planning?

Capacity planning is divided into three time periods: long-term (over one year), medium-term (3 to 18 months), and short-term (less than 3 months). Each period focuses on different operational and strategic needs, such as large investments, handling unexpected demand, or managing daily schedules.

What is the formula for calculating rated capacity?

The formula for calculating rated capacity is: Number of machines * hours per machine * percentage of usage * system efficiency. This calculation helps estimate the total output of a factory under ideal conditions.

How does the Economic of Scale concept apply to capacity planning?

Economies of scale refer to cost reductions that occur as production volume increases. In capacity planning, it suggests that larger production volumes lead to more efficient operations and lower costs per unit. However, diseconomies of scale can occur when excessive growth leads to inefficiencies and higher costs.

What are the implications of using a practical capacity approach?

Practical capacity involves maximizing output through strategies like overtime, additional labor, and reducing delays. It allows factories to reach higher production levels but may involve extra costs and resource strain.

How do you calculate the number of machines needed to meet monthly demand?

To calculate the number of machines needed, you must first determine the total number of working hours required based on demand, machine efficiency, setup times, and delays. Then, divide the total required hours by the available working hours per machine to determine the number of machines needed.