Form_146_NSWCIHEODTD_Capacity_Planning_Form-Exc.xlsx

Capacity Planning

II. Capacity Planning

show only the operating pattern for the specific part)

K Equipment Availability [(E-J)/E] - - - - - - -

For linked processes, see notes.

L Projected Quality Rate (%) - - - - - - -

M Net Planned Ideal Cycle Time (sec/part) For multiple cavities in one tool, see notes.

Planned production capacity / week [(E-J)*3600*L/M] - - - - - - -

&"-,Bold"&16FOUO - Not for Public Release &"-,Bold"&16Form 146

ICAS User Instruction

Capacity is to be demonstrated on all production processes, including internal sub-assembly and sub-tier components.

Capacity Verification The Initial Capacity Assessment Sheet consists of one main element: Capacity Planning (verification of production readiness).

The Initial Capacity Assessment Sheet is divided into 2 areas for ease of use. Each area has a heading at the top of the box. The headings are:

1. Key Information - Product / Customer Production / Capacity Revision Record

2. Capacity Planning

Data input The Initial Capacity Assessment Sheet has been divided into a number of easy to identify information boxes. Each box has a main heading to allow easy recognition. Within each box the user is required to input a variety of data. This manual will explain how to complete each section in turn.

Input & Calculation Cells: Data can only be input into the workbook in the cells on each sheet that require data. This ensures that the headings or other information cannot be accidentally erased or modified. These cells (input cells) are clearly identified as white in colour and with a solid outline around the box.

Cells that are grey in colour are calculation cells. The user cannot enter data into these cells. They calculate values according to specific formulae using data entered into the input cells.

KEY INFORMATION - Product & Production Information / Capacity Revision Record

The first Step in completing the Initial Capacity Assessment Sheet is to enter details of the part being analyzed. These Cells hold the basic information on the supplier and the part analyzed within the worksheet.

B. Customer Production Before the Initial Capacity Assessment can take place, the Annual quoted volume must be added. This information will be available through the buyer and may also be available in the Purchase Order.

Fill in volume quoted in RFQ in cell “Annual quoted volume (RFQ)” in section “1. Key Information.” Volume value that should be used is volume in peak production year multiplied with 10% for fluctuations during the year.

C. Capacity Revision Record.

Any revisions to the capacity Assessment of the process must be tracked using this section.

CAPACITY PLANNING

A cut of the Operating pattern is shown above with an example of data input for a process with seven operations. The Operating pattern gives the opportunity to give each operation a different operating pattern. The operating pattern input should mirror the true dedicated manufacturing time for each operation, e.g. by shared machines.

Input Cells: Process Description: Enter a brief Description of a process (e.g. final assembly, or inspection) Input Cells: Dedicated or Shared Process: Identify from a drop-down box, the process type – dedicated / shared.

Dedicated Processes A “dedicated” process is one, which is solely used for the part being analysed in this worksheet. For example, a test station may be a dedicated process.

A “shared” process is one which has many different parts manufactured on the process, and a more significant tool changeover time. It would be usual for such a process to manufacture parts in a batch production mode.

Examples of a shared process are:

· stamping press

· injection moulding machine

· heat treatment facility

· Input Cells: Shifts per day: - indicate the number of shifts in which each process operates per day.

· Input Cells: Total hours per shift – total number of hours for each shift.

. Input Cells: Hours/shift used for this part number (shared prod) - indicate the average number of hours per shift intended to be used for this partnumber.

· Input Cells: Personal Breaks – If the machine stops during personal breaks enter the length of time over one shift that the machine will not be operating. If the machine operates during personal breaks and is guaranteed to never run out of parts, then enter "0".

· Input Cells: Planned Maintenance – this is the length of time that is planned for the machine to be down during a shift for maintenance.

· Input Cells: Days per Week – indicate the number of days in which each process operates per week. Example: Supplier works 4 days 3 shifts each and on Friday only 1 shift should just enter: 4 working days plus 1/3 working day = 4.333 days / week [4,333 in European notation]

· Input Cells: Tool / Variant Changeover – Enter the changeover time for tool changes or module changes for the part in question. Changeover time is defined as the total time from last off previous part to checked first off new part.

· Input Cells: Changeovers / shift – Enter the frequency of tool / module change per shift.

· Input Cells: Inspections of facilities / shift - Enter the downtime required for unplanned equipment inspections or unplanned adjustments during a shift

· Input Cells: Breakdowns / shift – Enter all other projected downtime during a shift.

· Calculation Cell: The Equipment Availability is calculated automatically by using previous data.

Equipment Availability = (Total Planned Production Time – Downtime) / Total Planned Production Time

· Input Cell: Net Planned Ideal Cycle Time – Please provide the best estimate of the cycle time of the part on each process. The worksheet will use this data to calculate the Planned Production Capacity. This could also be a time taken with a stopwatch at the bottleneck operation. The measurement taken should always include the time for loading / unloading and inspection (Part-to-Part). Part-to-Part cycle time measurement requires that the operation being measured is not blocked or starved for at least two consecutive part cycles. Pick a point in the operation's cycle to begin timing and when the next part reaches that same point in the cycle, stop timing and record the elapsed time as the operation's cycle time. It is best to repeat this measurement at least 10 times (making sure that the blocked and starved condition is absent in each measurement) and take the average. Note: For multiple cavities in one tool the actual cycle time of the tool must be divided by the number of cavities in the tool (to provide a net cycle time per part).

· Calculation Cell: Required Cycle time needed to cover exact customer demand - "For Information Only" - the worksheet displays the Cycle time needed to cover exact customer demand, calculated from planned operating pattern, projected downtime and quality rate. This is to be compared to the Planned cycle time

· Calculation Cells: Planned production capacity per week. This is to be compared with the Customer Demand per Week.

Weekly Parts Available Actual weekly parts available 0 0 0 0 0 0 0 1 Percent above/below weekly demand

0 0 0 0 0 0 0 1 Customer weekly demand 0 0 0 0 0 0 0 1

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