Cut Capacity Planning Research Articles

A new MIP RCCP model for tackling tactical project planning

This paper proposes a new continuous-time linear mixed model for rough cut capacity planning (RCCP) adapted to tackle various tactical project planning scenarios. RCCP models are typically designed for the early phases of projects to decide the work package's execution intensities for each project planning period. The goal is to solve large-scale, complex instances while ensuring both optimality and efficient resolution times. We propose modifications to the constraints of one of the best models in this field to improve its resolution. Recognizing that overlap between two consecutive periods adversely affects the performance of the MIP solver, we introduce minimal, fictitious boundaries between these periods. Additional strategies, derived from analyzing initial constraints and solver behaviour, ensure solution optimality. The objectives considered are: minimising the costs of using external resources by setting the project's end date (Time-driven) and minimising the makespan (Resource-driven). The bi-objective case is also addressed. The improved model reduces the average number of dual simplex iterations of CPLEX by 72%. Moreover, only 0.7% of large instances remained unresolved with the new model compared to nearly 30% of instances with the previous best model. The fast resolution of a single-objective problem opens up opportunities for multi-criteria approaches, making the model adaptable to more complex needs in practice.

Analisis Kapasitas Produksi Menggunakan Metode Rough Cut Capacity Planning Pada CV Tahaki Multi Kreasi

CV Tahaki Multi Kreasi is a company engaged in interior, exterior and advertising. The number of requests for cabinet room products tends to fluctuate every month. In 2023, from January to December, CV Tahaki Multi Kreasi received 143 cabinet room order projects. To estimate the amount of demand, effective forecasting is needed. Forecasting uses methods namely Moving Average, Exponential Smoothing, and Trend Analysis. The most effective forecasting uses the Trend Analysis method which has the smallest forecasting error. The MAD value is 1.9005, MSE is 4.5343, and MAPE is 19.2362. The production schedule at CV Tahaki Multi Kreasi is carried out every two weeks for optimal results. Production capacity requirements are calculated using the Rough Cut Capacity Planning (RCCP) method. The RCCP method is used to determine the possibility of insufficient capacity or overload in determining production capacity.. The total capacity required in all work centers is 962 hours, while the total available capacity is 2016 hours. The analysis shows that there is no capacity shortage at each work station because the variance shows negative and the load percentage is 54.2%.

ANALISIS KAPASITAS PRODUKSI PHYLON UNTUK MENDUKUNG JADWAL INDUK PRODUKSI MENGGUNAKAN METODE ROUGH CUT CAPACITY PLANNING (RCCP) DI PT HANJIN INSOLE INDONESIA PURWAKARTA

PT Hanjin Insole Indonesia is a company that produces phylon for shoe products. PT Hanjin Insole Indonesia has two products: Airmax 270 and Airmax Dawn. The company needs to know the factory's capacity to meet consumer demand. The main factor causing the company to be unable to meet consumer demand is that demand in each period experiences unstable conditions, which results in it being unable to meet demand. The company needs to do production planning to predict demand and ensure that consumer needs are met on time. By using the forecasting method, the company can determine the demand needed. The Aggregate Production Plan is designed to manage the costs required. The Master Production Schedule allows the company to evaluate its production capabilities and anticipate changes in demand each period. At the same time, Rough Cut Capacity Planning helps assess the company's capacity to meet demand. This study shows that the required production capacity has not reached the available capacity, with a percentage of 77% of the company's capacity, so the master production schedule for next year is considered adequate and has the potential to be maximized.

Analysis Of Sugar Planning In PG Mojo Sragen

This study aims to analyze the planning of sugar production capacity is efficient or not in PG Mojo Sragen. Although the level of sugar production capacity in a particular year still exceeds capacity and also lacks capacity. The production capacity planning analyzed includes the available capacity and the required capacity of each station, namely the refining station, evaporation, cooking, turning, Waste Water Treatment Plant (WWTP), and stamfloor (sugar packaging place). The analysis method used is RCCP (Rought Cut Capacity Planning). The results showed that the comparison of the efficiency of each workstation which was said to be inefficient was found at the evaporation workstation, WWTP, and stamfloor. The three stations have lower available capacity compared to the higher required capacity. This research is expected to provide insight for PG Mojo Sragen to increase available capacity through better alternatives.

Analisa Kapasitas Produksi Line Welding LDT Menggunakan Metode Rough Cut Capacity Planning pada PT. ABC

PT ABC is a limited liability company engaged in heavy automotive production that has many products such as medium trucks, small trucks, bus chassis, engines and other spare parts. In assembling a Light Duty Truck through several work stations and must go through production schedule planning to meet the requested production demand. In the case of the welding line, there is a mismatch in production results with the planned production results at the end of the production period not in accordance with the scheduling carried out. So it is necessary to analyze production capacity using the calculation of Rough Cut Capacity Planning, after the calculation it is found that there are still several work stations that experience a lack of production capacity of -849 hours and excess capacity for production throughout the 12-month period. This shows that the lack of efficiency of the available capacity at each station in the LDT welding line so that it cannot produce according to the planned production demand

Arabika Coffee Production Capacity Planning with Rough Cut Capacity Planning (RCCP)

Industrial competition causes companies to be required to increase efficiency, produce quality products and deliver products on time. UMKM Kaana Toraya Coffee is a manufacturing industry that processes Coffee and Food & Beverages. Demand for Kaana Toraya Coffee tends to fluctuate. So a Production Plan is needed that is adjusted to production capacity. The aim of this research is to forecast future needs, validate the production plan and design a master production schedule. Forecasting needs using the Weighted Moving Average and Single Exponential Smoothing methods to analyze production plans using the Rough Cut Capacity Planning method with the Bill of Labor. The forecasting results using the Single Exponential Smoothing method with a constant of 0.9 are used as a production plan based on the smallest accuracy. RCCP shows that there is a lack of capacity in the roasting work center. The alternative that was implemented was optimizing the utility of working hours, but there was a lack of capacity, so the second alternative wa to move the workload to the previous period. The Master Production Schedule with RCCP for the period July 2023 to March 2024 in kilograms are 147, 173, 148, 149, 150, 159, 147, 144, and 156.

Integration of Rough Cut Capacity Planning (RCCP) and Capacity Constraint Resources (CCR) to Minimize the Risk of Uncertainty in Fulfilling Production Material Supply

Integration of Rough Cut Capacity Planning (RCCP) and Capacity Constraint Resources (CCR) to Minimize the Risk of Uncertainty in Fulfilling Production Material Supply

Hospital rough cut capacity planning in a General Surgery service

Hospital services constitute a fundamental pillar in the development of society. The objective of this article is to provide medium-term capacity planning improvements in a General Surgery service. A procedure was designed for capacity planning based on process analysis and design as well as the patients’ clinical characteristics. Some of the main results were: the demand of the Major Diagnostic Categories was predicted, the rooms were identified as the limiting resource in this kind of service, where an 82.82 % of them were used, the necessary wards reservations were calculated for the year 2021, with a rate of 163, 96 and 59 times for incisional, inguinal and umbilical hernia surgeries respectively, and a system of capacity improvement actions which were projected. The analysis of capacity using the proposed heuristic method makes possible to identify limiting resources, enhance performance and devise strategies to meet the demand.

Wind Turbine Production Planning in Logistic Systems

Production planning is very important in an industrial company as well as planning in Logistics. The purpose of implementing production planning in a company is to minimize costs incurred and maximize profits. This research is practicum-based research in the laboratory with the object of observation in the form of a wind turbine toy. This object will be processed through 5 stages in the production process starting from forecasting, RCCP (Rough Cut Capacity Planning), MRP (Material Requirement Planning), CRP (Capacity Requirement Planning), and Line Balancing. forecasting results are carried out with 12 future periods producing 232,888 units, RCCP balance between available capacity and required capacity, MRP using the lot sizing technique obtains the cheapest cost per unit Rp.142,179 with the LTC (Least Total Cost) method when compared to other MRP methods, namely LFL (Lot for Lot), POQ (Period Order Quantity), PPB (Part Period Balancing), EOQ (Economic Order Quantity), and LUC (Least Unit Cost), CRP by calculating the number of machines and working time, and line balancing which results in a decrease in track ineffectiveness from 42% to 22% and Smoothness Index from 476,662 to 189,703.

PERENCANAAN KAPASITAS PERCETAKAN ETHICA GROUP MENGGUNAKAN METODE ROUGH CUT CAPACITY PLANNING

PT Ethica Megah Madani is a large-scale Muslim clothing manufacturing company. Even the production reaches 1.224.600 pcs per year. Meanwhile, the product produced are Muslim clothes for adults and children, men and women, headscarves, socks, with various different market segments. While the packaging for these products still uses vendors, the company wants a new business unit in the form of packaging printing for its product needs. In starting a new business unit, of course, planning become a reference when the business or production is already running. This study aims to plan the packaging production capacity so that the needs are met. Production capacity is the maximum number of units that can be produced in a certain period of time using available resources. The method used is Rough Cut Capacity Planning (RCCP), which is a method for calculating general capacity requirements and comparing them with available capacity. Next, perform an analysis on machines that lack capacity by adding time. From the processing results, it is known that there is one machine that lacks capacity and needs to be added, namely the screen printing machine

ANALISIS KAPASITAS PRODUKSI PADA LINI PRODUKSI BARU FORD P702 HVPO DENGAN PENDEKATAN METODE ROUGH CUT CAPACITY PLANNING (STUDI KASUS DI PT CSB)

ABSTRACTThis research is to analyze capacity requirements and availability on the production line. This research in PT CSB project FORD P702 HVPO production line. Data analysis used the Rough Cut Capacity Planning (RCCP) method by measuring work (time study), forecasting, aggregate planning, master production schedule and capacity analysis with RCCP.Based on research, standard time is 745 seconds / unit for new prodject FORD P702 HVPO. The best forecasting method is use Single Moving Average with an MAD error value of 0.04 and MSE error value of 0.021. Aggregate planning calculation results is 27144 units per year with cost of Rp 49,563,348 per year. And the conclusion is the capacity of the FORD P702 HVPO production line is sufficient and feasible to meet customer needs. This research is calculated based on the total production capacity of 19,958,400 seconds per unit in 1 year and the total required capacity of 18,618,775 seconds per unit in 1 year.

Analysis of production capacity planning to meet the consumer request using the Rough Cut Capacity Planning (RCCP) method in PT. Maccon Generasi Mandiri Makassar, Indonesia

Analysis of production capacity planning to meet the consumer request using the Rough Cut Capacity Planning (RCCP) method in PT. Maccon Generasi Mandiri Makassar, Indonesia

Analysis of production capacity planning to meet the consumer request using the Rough Cut Capacity Planning (RCCP) method in PT. Maccon Generasi Mandiri Makassar, Indonesia

Maccon Generasi Mandiri Makassar company is one of a manufacturing company engaged in the production of light brick AAC (Autoclaved Aerated Concrete). PT. Maccon Generasi Mandiri Makassar has a production capacity of 15024 〖 m〗^3 in a month or 180288 〖 m〗^3 in a year. However, with this capacity, the company is often unable to meet high consumer demand of 181450 〖 m〗^3 in a year due to less than optimal engine performance, a number of hours of work and an unbalanced workforce in the producing light brick of ACC (Autoclaved Aerated Concrete). This requires the company to plan the optimal production of capacity in order to fulfill the consumer demand in a timely and appropriate amount so that the expected of company profits will be increased. The purpose of this research is to plan production capacity in the future based on the demand rate of the consumer using the Rough Cut Capacity Planning (RCCP) with the method is Bill of Labor Approach (BOLA) technique. Based on the data processing which has been done, the recommended made were a combination of engine additions and working time. This is realized to fulfill the lack of production capacity. For the January Period = 19872 hours/month, February = 19008 hours/month, March = 19872 hours/month, April = 19008 hours/month, May = 18144 hours/month, June = 18144 hours/month, July = 19872 hour/month, August = 18144 hours/month, September = 17280 hours/month, October = 18144 hours/month, November = 18144 hours/month, December = 17280 hours/month.

Perencanaan dan Pengendalian Produksi Dalam Sistem Logistik (Pendekatan Berbasis Praktikum Laboratorium)

The concept of Production Planning and Control is closely related to logistics activities, including in determining the production of a product. Production planning and control aims to get a complete picture of how to plan and control production in the industry of each company, so that all costs can be reduced. Production planning, Rough Cut Capacity Planning (RCCP), Material Requirement Planning (MRP), Capacity Requirement Planning (CRP), and Line Balancing are some of the steps that need to be done in providing an overview of the production planning and control system at the "Tamiya" Company. Production planning results in the amount of "Tamiya" production in a certain period by considering SEE and the most appropriate production strategy that results in total costs. MPS validation considerations are the output of the RCCP calculation, a comparison of the ratio of the required capacity to the capacity of the company. The MRP stage reduces production due to material unavailability, the result is the best material scheduling based on the lot sizing method which provides the lowest cost. CRP generates Planned Input and Planned Output per work station to see the balance between load and capacity. Line Balancing functions to balance assignments through the Ranking Position Weight (RPW) and Presedence Diagram methods, getting results in the form of updating the layout of the assignment so that the efficiency of the production line can be improved

EVALUASI KAPASITAS PRODUKSI BAN MENGGUNAKAN METODE RCCP DENGAN PENDEKATAN BOLA

Capacity planning in a company's production process needs to be considered so that the products produced meet consumer demand. PT X, is a manufacturing company that focuses on tire production. One type of large-sized tire product that has the highest demand is the ABC type with a sTabel production amount per month and demand that goes up every year. In terms of fulfilling customer demand, especially requests for large tires with type ABC, PT X often has difficulty in meeting consumer demand, this happens because the capacity of the machine is not available. Therefore, the existing production capacity must be evaluated to find out whether the available capacity is sufficient with the required capacity. To analyze this problem, the Rough Cut Capacity Planning (RCCP) method, this method is to analyze and test the determination of capacity in the master production schedule. Calculation of available capacity and capacity required in a year is carried out for the process carried out, namely: Building, Spreading and venting, curing, and Trimming. For the building and trimming process, it is found that the decision of the acupacity is fulfilled, while the Spreading and venting process is required to add 1 machine, and the curing process is required to add the machine according to the number of requests per month. From these results it can be given a proposal that needs to be considered in meeting the capacity to meet consumer needs while still paying attention to production costs.

Implementation of The Rought Cut Capacity Planning (RCCP) Methods for The Planning of Bottled Drinking Water Production Capacity: A study case

Syifa Ltd is a manufacturing company that produces bottled drinking water with several types of products produced from their production floor. The main objective of this research was to predict the total quantity production of the 220 ml bottled mineral water to meet the consumer demand as scheduled time. In forecasting the demand for production of the 220 ml glass bottle packaging, the methods used were the Weighted Moving Average (WMA) method and the Single Exponential Smoothing (SES) method by comparing the size of forecasting errors using Mean Absolute Deviation (MAD), Mean Square Error (MSE), and Mean Absolute Percentage Error (MAPE). To determine the supply of glass bottles used the EOQ (Economy Order Quantity) method to determine the purchase of the most economical glass bottles. The Rought Cut Capacity Planning (RCCP) analysis result shows that there was insufficient capacity/lack of capacity in the filling and packing work center. Alternative capacity management used to optimize production utility to 95% and make capacity adjustments (re-adjustment). So that alternative capacity management was able to meet the capacity shortages that occur

Comparison Study Among Production Planning Research in Some Papers and Industries in Indonesia

Keeping company exist means the company must have good policies related to sales activity. The solution is by implementing production planning which include forecasting, aggregate planning, disaggregate planning, making master production schedule, making rough cut capacity planning, material requirement planning, and capacity requirement planning. Every companies have their own unique situation which make the best method for each company is different. The aim of this paper is to determine the gap among sore researches and studies about production planning ind Indonesia. For methodology, this paper will be described by comparison literature study, so in the future research could give contribution to the blank area of study.

Production Capacity Optimization with Rough Cut Capacity Planning (RCCP)

One of the factors supporting the company’s success in achieving its goals is the ability to meet demand and provide satisfaction to customers. A musical instrument industry makes products with a make to order system, so that it requires the accuracy and smoothness of the production process to meet the demand in accordance with the specified time. Based on data on average total daily production of Spray and Sanding Balikan Factory 2, it known that there is still often an imbalance between the actual productions of the planned production at regular work time. This study aims to analyse and evaluate the capacity of production resources and facilities. The Rough Cut Capacity Planning (RCPP) method is a method that can show a comparison between the actual capacity available and the capacity needed. Based on the research results, workload rearrangement must be carried out to distribute labor and increase work hours 90 minutes and 120 minutes so that demand can be fulfilled.

Application of Theory of Constraints in Bottleneck Work Stations Optimization

Manufacturing industries engaged in making of instant noodles in Medan city have problems in production planning. The process studied is the manufacture of GCGEP, GCST and G-1000GSP products. The constraints faced by the company are the presence of bottlenecks on mixing and cooking work stations due to differences in capacity between the work station and the previous work station, namely the sieving work station and dough forming work station. Bottleneck work stations happens in mixing work stations in January, February, March, May, June, July and August 2014 as well as cooking work stations in January, May and July 2014. This study uses the principle of continuous improvement of Theory of Constraints (TOC) to eliminate constraints on bottleneck work stations and to facilitate the overall production flow. In applying TOC, to optimize the production master schedule and to know the maximum advantage cost, linear programming method is used. After the optimal master schedule results are known, revisions to rough cut capacity planning are carried out and the result shows that the bottleneck work station found has become a non-bottleneck work station.

PERENCANAAN DAN PENGENDALIAN KAPASITAS PRODUKSI PRODUK RAKITAN RADIO TIPE SOUNESS SNI 4250

Production system take an important role in industries, especially in manufacturing industries. This role determine the keys of successful company. Production process is an activity which produce finished product from raw material that involve machine, energy, and technique knowledge. Production process is real activity and can be seen by human being. The problems those always be faced in indutries management’s are the arrangement of production schedule, such lack of inventory or overstock once the settlement of production process isn’t on time. Production planning and control is activity to determine what product that will be produced, how many product that will be produced and how many labors needed in production processes. By using production planning and control’s method, those problems can be minimalized. Aggregate planning is one of production planning a.nd control’s method. By using this method, production planning could be done by using unit of replacement product so that the output of this planning isn’t declared in individual product. So, the output of aggregate planning isn’t planning in form of individual product but aggregate’s product. There are some strategies on aggregate planning such as pure strategy on aggregate planning and mixed strategy on aggregate planning. In this research, method of aggregate planning that used is optimization approach by linier rule. This method used to make long term planning and middle term planning. Long term planning consists of product forecasting and aggregate planning. The middle term planning consist of master production schedule and rough cut capacity planning. The result of this research is capacity needed and capacity available to determine which work center is drum and which isn’t. Conclusion of this research that capacity of each work center in perioad january to december 2018 is non drum. This indicate the good scheduling in capacity planning.