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CAPACITY
PLANNING
React to planning while respecting constraints
Material planning tools are helpful but have one major weakness – they assume infinite production capacity.
The result is the creation of production schedules that are often impossible to achieve. This typically leads to
production schedules that do not reflect reality and problems in fulfilling customer commitments on-time. For
manufacturers to overcome this challenge, they must be able to apply constraints to their production plans.
GLOVIA G2 Capacity Planning is a Java-based, memory resident planning tool that enables manufacturers to
determine the most effective way to execute production schedules and respect material plan constraints. The
module applies machine and inventory constraints to all production orders including those entered manually
and those generated by GLOVIA G2 Material Requirements Planning, Master Production Scheduling or Project
Requirements Planning.
GLOVIA G2 Capacity Planning can provide many business benefits including:
• Increased production throughput
• Reduced changeover times via set-up optimization
• Identification and elimination of production bottlenecks
• Minimized costs associated with unplanned downtime, overtime and idle time
• Reduced production disruption from machine repair and/or maintenance
• Increased visibility into an accurate production plan that reflects an achievable production schedule after
taking into account Capacity Constraints and the ability to accurately predict customer deliveries.
Capacity Planning is a highly visual and graphical application that displays a view of the shop load based on
both the existing released production orders and planned production orders that have not yet been created.
This enables users to see the overall long term production picture and make any necessary adjustments. For
example, a work order may be given a start date & time, and, a completion date & time based on material
planning requirements. However, due to machine capacity constraints, the work order cannot be completed on
time. Capacity Planning helps manufacturers to first see the problem exists and then determine the best way
to overcome the problem by allowing them to simulate the impact of taking various actions like running more
shifts, adding capacity or taking some other action.
The solution increases productivity and throughput by accounting for constraints, minimizing changeovers and
sequencing similar jobs together.
Providing Production Visibility
By scheduling production around both the material and machine capacity constraints - Capacity Planning provides
manufacturers with realistic production and material supply plans. These plans are provided via a highly graphical,
highly visual, user interface that displays information in Gantt and Bar charts that immediately identify future
bottlenecks and shortages using color coding and visual alerts and indicators. This ability to have forward visibility
of a realistic production plan and the problems that will occur if nothing is done - enables manufacturers to either
change the plan or adjust capacity before production and customers are impacted.
to start in the next 5 days and prioritize them based
on (1) order priority and (2) start date/time and then
schedule them forward from the current date/time as
soon as material and machine capacity is available.
In the long term they would typically also wish to
include production orders that are planned but not
created yet. For longer term planning they may wish
to schedule backwards based on due date. They
may also wish to schedule with infinite capacity and
infinite materials so that they can see how much they
would need to increase the capacity by adding more
equipment or changing shifts and/or changing the
materials plan. In longer term planning these changes
become more feasible.
Real time Integration, with Direct Access
to all GLOVIA G2 Transactions
Capacity Planning’s memory-resident data model
is a seamless extension of GLOVIA G2’s realtime database. The information used in Capacity
planning is always based on accurate, up-to-theminute information and NOT on a snapshot.
As events transpire throughout your company the
changes are immediately reflected and the highly
visual displays updated. When orders are added,
changed, rescheduled or completed, inventory
is received, materials are issued, production is
behind or ahead of schedule, etc. – the changes
are immediately visible and the impact of those
changes on all orders in the future production
schedule can be quickly assessed.
Capacity Planning includes the Following Capabilities:
Because Capacity Planning is a completely
integrated part of the GLOVIA G2 ERP application,
the GLOVIA G2 ERP screens can also be directly
accessed from the Capacity Planning application.
For example, a Work Order routing or BOM may
be directly accessed and maintained in order to
resolve a material constraint or machine capacity
bottleneck. In solutions that are not fully integrated
this ability to interact and see the result of making
real time adjustments to production orders and
supplies can be difficult or impractical.
“What-if” Planning
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Planning of work orders, repetitive schedules and
planned orders
Forward and backward scheduling with limited and
unlimited machine capacity and material options
Multiple “what-if” planning
Scheduling in hours minutes and seconds
Providing “drag and drop” planning capabilities
Configurable, detailed order and operational
information including “mouse over” and
“annotation” capabilities that enable key information
to always be available at the users ‘fingertips’
Unlimited shift patterns – Allow shift patterns to be
associated to the whole plant, departments, workcenters, or specific to a machine
Capacity Planning allows manufacturers to run
and compare multiple “what-if” planning scenarios
to find the most effective use of available capacity
and materials to meet commitments.
Long Term and Short Term Planning
Capacity Planning provides for the definition of short
term, and, long term planning horizons and apply
different planning rules and priorities for each. This
powerful feature allows customers to create a highly
personalized planning mechanism that best matches
their needs.
For example: A manufacturer may identify a ‘rolling’
short term planning horizon of 5 days and a Long term
planning horizon of 3 months, 6 months, 12 months or
even more.
In the short term, they may want to keep production
schedule very stable with the minimum changes, but,
there will always be the ‘late’ orders to catch-up on, and
some orders that become escalated as a high priority.
Given this type of goal, they may decide to take all
incomplete production orders that are past due or due
Fujitsu Glovia, Inc.
2250 East Imperial Highway, Ste. 200
El Segundo, CA 90245-3457
Tel: +1 800 223-3799
+1 310 563-7000
Fax: +1 310 563-7300
Email: [email protected]
www.glovia.com