Capacity Planning in “Build to Order” Sunglass Manufacturing Industry
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MANUFACTURING INDUSTRY\Capacity Planning
Capacity Planning in "Build to Order" Sunglass Manufacturing Industry
Key Points
- Huge Variation in Product Mix - Build to Order
- Large seasonal variation in Demand
- Capacity Planning
Client's Challenge
- N number of variations in the product as it is a Build to order (BTO)
- Immense variations in cycle times due to changes in the property of lenses
- Manual/Auto Operations operated individually or in batches
- Wide variations in weekly demand throughout the year
- Reduce order lead time to maintain the reputation of on-time delivery
- Predict new shift patterns to meet future demand, if any
PMI's Approach
- Data analysis, 2D model building, verification & validation
- Analysed shift pattern and its effects on weekly throughput
- Used MODAPTS to reduce Process lead time in manual operations
- Integration of shipment schedule within the Model to study Order lead time
Findings & Recommendation
- The study showed current shift pattern can not meet the future demand
- Devised a new shift pattern to meet a future forecast for the next 5 years
- Identified the maximum production limit beyond which capacity expansion is required
