Program Overview
This hands-on program is designed to help manufacturing, operations, and planning professionals effectively manage capacity under uncertainty. Participants will learn how to evaluate short- and long-term capacity scenarios using demand variability, machine uptime, labor availability, and supplier constraints. The course introduces tools such as rough-cut capacity planning (RCCP), finite scheduling, and bottleneck identification, along with TOC (Theory of Constraints) principles. Through simulation-driven activities, attendees will model realistic scenarios—like surge demand or supplier failure—and devise proactive plans to balance capacity, improve throughput, and minimize downtime.
Features
- Model capacity scenarios based on changes in demand, resource availability, and production load
- Apply RCCP and finite capacity planning to align load vs. capacity
- Use Theory of Constraints to manage and de-bottleneck critical work centers
- Develop contingency plans for labor, supplier, or equipment-driven constraints
Target audiences
- Industrial Engineers
- Supply Chain Professionals
- Production Managers
- Plant Team Leads
Curriculum
- 5 Sections
- 20 Lessons
- 1 Day
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- Fundamentals of Capacity Planning4
- 1.1Concepts: Rated vs Effective Capacity, Bottlenecks, Resource Availability
- 1.2Key Terms: RCCP, Machine Uptime, Headcount Flexibility, Outsourcing Thresholds
- 1.3Situational Insight: Paint manufacturer exceeded planned output by shift restructuring
- 1.4Exercise: Map rated vs actual capacity across 2 resources (labor/machine)
- Scenario Building for Capacity Planning4
- Managing Constraints Strategically4
- 3.1Concepts: Theory of Constraints (TOC), Drum-Buffer-Rope, Decoupling Point
- 3.2Key Terms: Constraint Resource, WIP Buffering, Lean Bottleneck Elimination
- 3.3Real-life Insight: Automotive firm ran critical resource 24×7 post TOC analysis
- 3.4Exercise: Participants identify key constraint and propose 3 mitigation levers
- Capacity vs Inventory vs Service – Trade-off Planning4
- 4.1Concepts: Demand Volatility, Campaign Planning, Response Strategies
- 4.2Key Terms: Capacity Reservation, Split Loads, Sub-contracting
- 4.3Case Study: Pharma firm used inventory pre-build strategy to bypass lead-time issues
- 4.4Exercise: Build a trade-off decision matrix across capacity, cost, and service
- KPI, Governance & Planning Calendar4