5) Rough-Cut Capacity Planning (RCCP)

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Departemen Teknik Industri FTI-ITB

TI-3122 Perencanaan dan Pengendalian Produksi

Rough-Cut Capacity Planning

Laboratorium Sistem Produksiwww.lspitb.org

©2003

TI3122-Perencanaan dan Pengendalian Produksi - Minggu 5 2


Hasil Pembelajaran

• UmumMahasiswa mampu menerapkan model matematik, heuristik dan teknik statistik untuk menganalisis danmerancang suatu sistem perencanaan dan pengendalianproduksi

• KhususMemahami konsep perencanaan kapasitas dan mampumenghitung kebutuhan kapasitas serta pengendalianaktivitas produksi

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Capacity Planning

Productionplanning

Materialrequirements

planning

Masterproductionschedule

Productionactivity control

Demandmanagement

Final assemblyscheduling

Resourcerequirement

planning

Rough cutcapacityplanning

Capacityrequirement

planning

Input/outputcontrol

Long range

Medium range

Short range

Capacitymanagementtechniques



Rough Cut Capacity Planning

• RCCP → alat untuk memverifikasi MPS

• Hambatan dalam penerapan Manajemenkapasitas:

Perlu data yang banyakProsesnya iteratif sehingga memerlukan banyak waktuMPS tidak stabil

• Tiga teknik RCCP:Capacity planning using overall factors (CPOF)Bill of Labor Approach (BOL)Resource profile approach (RP)

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Master Production Schedule (x1000 units)

Month Forecast Regular Overtime Total Inventory15

January 22 15 0 15 8February 8 15 0 15 15March 10 15 0 15 20April 10 15 0 15 25May 20 15 0 15 20June 14 15 0 15 21July 8 15 0 15 28August 8 15 1 16 36September 12 15 4 19 43October 15 15 4 19 47November 30 15 4 19 36December 40 15 4 19 15

197 180 197



Capacity planning using overall factors (CPOF)

• Data yang diperlukan:MPSWaktu yang diperlukan untuk memproduksi suatuprodukProporsi waktu yang digunakan untuk setiap sumberdaya

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CPOF (Contoh)

• JanuaryTotal capacity requirement = 0.22 x 15000= 3300Historical proportion for Lamp Assembly = 0.10 / 0.22 = 0.45Lamp Assembly capacity requirement = 0.455 x 3300 = 1501.5

Work Historical TotalCenter 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 19,719.7Oven 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 1,950.3Base 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 9,838.2Plastic 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 3,943.9Socket 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 7,887.9Total 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 LAXXLamp Assembly 0.10 hrOven 0.01 hrBase Forming 0.05 hrPlastic Molding 0.02 hrSocket Assembly 0.04 hr

0.22 hr

Month



Bill of Labor Approach (BOL)

• Data yang diperlukan: sama dengan CPOF

• Jika ada n produk, maka:Kapasitas yang diperlukan = untuk seluruh i,jDimana:

– aik = waktu yang diperlukan produk k di stasiun kerja i– bkj = jumlah produk k yang akan diproduksi pada periode j

ba kj

n

kik∑

=1

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BOL (Contoh)

• JanuaryLamp Assembly capacity requirement = 0.10 x 15000 = 1500

Work Center TotalJan 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 19,700Oven 150 150 150 150 150 150 150 160 190 190 190 190 1,970Base Forming 750 750 750 750 750 750 750 800 950 950 950 950 9,850Plastic 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 7,880Total 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 LAXXLamp Assembly 0.10 hrOven 0.01 hrBase Forming 0.05 hrPlastic Molding 0.02 hrSocket Assembly 0.04 hr

Month



BOL: Two products, two month, two work centers

P1 P2 M1 M2 M1 M2Workcenter Product Workcenter

WC1 a11 a12 P1 b11 b12 WC1 c11 c12

WC2 a21 a22 P2 b21 b22 WC2 c21 c22

Master scheduleMonth

RCCPMonth

Bill of laborProduct

bac kj

n

kikij ∑

=

=1

babacbabacbabacbabac

2222122122

2122112121

2212121112

2112111111

+=

+=

+=

+=

P1 P2 M1 M2 M1 M2Workcenter Product Workcenter

WC1 0.3 0.2 P1 100 200 WC1 90 140

WC2 1 0.7 P2 300 400 WC2 310 480

Product Month MonthBill of labor Master schedule RCCP

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Resource profile approach (RP)

• Metode perhitungan mirip BOL + mempertimbangkan lead-time offset



RPA (Contoh)

• JulyLamp Assembly = 0.1 x 15000 (MPS July) = 1500Oven = 0.01 x 16000 (MPS August) = 160Base forming = 0.05 x 19000 (MPS September) = 950

TotalWork 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 19,700Oven 150 150 150 150 150 150 160 190 190 190 190 0 1,820Base Forming 750 750 750 750 750 800 950 950 950 950 0 0 8,350Plastic Molding 300 300 300 300 300 300 320 380 380 380 380 0 3,642Socket Assembly 600 600 600 600 600 600 640 760 760 760 760 0 7,280Total 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

Department 2 1 0Lamp Assembly 0 0 0.1Oven 0 0.01 0Base Forming 0.05 0 0Plastic Molding 0 0.02 0Socket Assembly 0 0.04 0

Month

Months Before Due Date

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RPA:Two products, two work centers, three month horizon, three month lead time

Resource Profile Master schedule RCCPMonth

2 1 0 M1 M2 M3 Work M1 M2 M3

Product Product Center p1 p1 WC1

p2 a212 a212 a210 p2 b21 b22 b23 WC2 c21 c22 c23

2 1 0

p2 a222 a221 a220

c12 c13c11b12 b13

Work Center 2

p1 a122 a121 a120

a110

Work Center 1

Month

b11

Time toDue Date

a112 a111

babacbabababac

babababababacbabac

babababacbabababababac

232201312023

2322122220131211212022

23222222212122013112121211112021

232101311011

2321122210131111211011

23212222112121013112121111111011

+=

+++=

+++++=

+=

+++=

+++++=

5) Rough-Cut Capacity Planning (RCCP)

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