Production Capacity Planning

We start from the full operation of a workcenter and subtract the factors that genuinely reduce capacity: planned maintenance and downtime, multi‑machine operation (the machine waiting for an operator), deviations from cycle times, inefficiency, setups, and scrap with rework. The result is capacity you can rely on, not a theoretical maximum.

Green confirms the workcenter keeps up with demand. Yellow is a warning: total capacity is sufficient, but work piles up on one busy machine even though it could be redistributed. Red marks a critical bottleneck: capacity falls short even in total, and without a new machine or a change in production the demand will not be met.

We compare demand separately against machine and labor capacity – the constraint can sit on either side. For people, we track headcount, per‑shift targets and hours actually worked. The model also includes external capacity (dual sourcing), so you immediately see how much of the missing capacity subcontracting covers.

Alongside the baseline plan you create a simulated scenario (say, higher demand for selected products, more operators or a new machine) and the tool compares both states workcenter by workcenter. You see precisely where the scenario creates – or relieves – a bottleneck before you roll the change out in reality.

Yes – and it is a more common starting point than you would think. You don’t need perfect cycle times or flawless master data. We start with what you have. The tool actually surfaces the discrepancies quickly: the gap between theoretical and historical utilization points to the exact places where cycle times don’t match reality. Data cleanup then has a concrete target instead of a blanket revision.

Between them – each solves a different level of control. Excel shows aggregates but hides bottlenecks, the split between machine and labor capacity, and scenarios. APS runs the operational detail: daily plans, job sequencing on machines, changeover minimization. It works with released production orders, not a long‑term forecast, so the mid‑ and long‑term capacity outlook is often missing entirely. Capacity Tool targets exactly that outlook: it works with the master plan and the forecast, runs on Power BI over your data, and replaces neither ERP nor MES. If you move to APS later, the data analysis from the project carries over.

A typical project comes in at tens of thousands of euros, depending on the number of machines and workcenters and the scope of simulation modules. It includes monthly service support covering adjustments, further development and any incidents. You pay for a tailored implementation, not licenses for yet another piece of software. For comparison: APS systems with a capacity module mean an order of magnitude larger investment and years of rollout. Capacity Tool is the interim step that answers your capacity questions at a fraction of the cost and time.

Routine changes (new orders, items, shift adjustments) flow in automatically with data refreshes from your systems. Structural changes – a new workcenter, a different view layout or new traffic‑light logic – are handled by us as part of support. You don’t need your own Power BI developer to run it.

The tool is fully configurable. Views can be split by plant, hall or department, and we adapt the filters to your structure. The same traffic‑light and scenario logic then works at the level of a single workcenter or a whole group.

Day‑to‑day work belongs to the production planner: checking bottlenecks, moving work, evaluating scenarios. The production director uses the overview reports for investment and order decisions. Purchasing and HR pull data on capacity gaps – whether that means subcontracting or hiring.

ERP exports (orders or the demand plan), routings with cycle times, a list of workcenters and machines, and the shift calendar. The data doesn’t have to be perfect – we start with what you have.