# SAP Work Center Capacity Planning Calculator

> Source: https://netray.co/tools/sap-capacity-planning-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Calculate available capacity, capacity requirements and load percent for a work center from shifts, utilization, setup and run times.

## Category

sap

## Erp

SAP S/4HANA

## Industry

Discrete Manufacturing

## Audience

- Production planner
- SAP PP consultant
- Plant manager

## Tool

**Kind:** calculator

**Inputs:**

#### Working days in period

**Key:** days

**Type:** number

**Default:** 20

**Min:** 1

**Max:** 31

**Step:** 1

**Unit:** days

**Help:** Factory calendar working days.

#### Shifts per day

**Key:** shifts

**Type:** select

**Default:** 2

**Options:**

##### 1 shift

**Value:** 1

##### 2 shifts

**Value:** 2

##### 3 shifts

**Value:** 3

#### Net hours per shift

**Key:** shift_hours

**Type:** number

**Default:** 7.5

**Min:** 1

**Max:** 12

**Step:** 0.25

**Unit:** hours

**Help:** Shift length minus breaks.

#### Number of individual capacities

**Key:** caps

**Type:** number

**Default:** 2

**Min:** 1

**Max:** 50

**Step:** 1

**Unit:** machines

**Help:** Parallel machines or operators in the work center.

#### Capacity utilization

**Key:** utilization

**Type:** number

**Default:** 85

**Min:** 1

**Max:** 100

**Step:** 1

**Unit:** %

**Help:** Planned utilization percentage in the capacity header.

#### Setup per lot

**Key:** setup_min

**Type:** number

**Default:** 45

**Min:** 0

**Step:** 5

**Unit:** min

#### Run time per unit

**Key:** run_min

**Type:** number

**Default:** 3.2

**Min:** 0

**Step:** 0.1

**Unit:** min

#### Lot size

**Key:** lot_size

**Type:** number

**Default:** 100

**Min:** 1

**Step:** 10

**Unit:** units

#### Lots in the period

**Key:** lots

**Type:** slider

**Default:** 30

**Min:** 1

**Max:** 80

**Step:** 1

**Unit:** lots

**Outputs:**

#### Available capacity

**Key:** available_h

**Expr:** days * shifts * shift_hours * caps * utilization / 100

**Format:** hours

**Description:** Operating time times individual capacities times utilization.

#### Setup requirement

**Key:** setup_h

**Expr:** lots * setup_min / 60

**Format:** hours

#### Run requirement

**Key:** run_h

**Expr:** lots * lot_size * run_min / 60

**Format:** hours

#### Total capacity requirement

**Key:** required_h

**Expr:** setup_h + run_h

**Format:** hours

#### Capacity load

**Key:** load_pct

**Expr:** required_h / available_h * 100

**Format:** percent

**Primary:** true

**Description:** Above 100 percent means the period is overloaded.

#### Free capacity

**Key:** free_h

**Expr:** available_h - required_h

**Format:** hours

**Primary:** true

#### Maximum lots that fit

**Key:** max_lots

**Expr:** floor(available_h * 60 / (setup_min + lot_size * run_min))

**Format:** integer

**Description:** Whole lots possible within available capacity.

**Chart:**

#### Capacity load vs lots in the period

**Type:** line

**X:** lots

**From:** 1

**To:** 80

**Steps:** 40

**Series:**

- load_pct

**Disclaimer:** Simplified single work center model. SAP capacity evaluation (CM01, CM02, CM04 and similar) uses your factory calendar, shift sequences, formulas and operation scheduling, so results can differ.

## Content

**Intro:** Before you run capacity leveling in SAP, it helps to know if a work center can carry the load at all. This calculator gives you a quick check: available hours from shifts, machines and utilization, required hours from setup and run time, and the resulting load.

**Sections:**

#### How to use the calculator

**Body:** Enter the working days, shifts, net hours and number of individual capacities for the work center. Add the utilization rate you use in the capacity header, then the setup per lot, run time per unit, lot size and number of lots. Read the load percent first. If it is above 100, the max lots output shows how many lots fit, and the chart shows how the load grows with lots.

**Bullets:**

- Use net shift hours after breaks
- Match utilization to the capacity header value
- Compare max lots to your current plan

#### The formulas behind it

**Body:** Available capacity equals working days times shifts times net hours times individual capacities times utilization. This mirrors how SAP derives available capacity from operating time, number of individual capacities and capacity utilization. Required capacity is setup per lot plus run time per unit times quantity, converted to hours. Load is required divided by available, shown as a percent. Free capacity is the difference.

#### Reading the result

**Body:** A load around 80 to 90 percent in a period is typically workable, since breakdowns, rework and rush orders need room. Above 100 percent, either move orders to another period, add shifts or machines, reduce setup through lot size changes or use an alternative work center. Try changing lot size: larger lots cut setup hours but raise stock and lead time.

#### Common mistakes

**Body:** Counting utilization twice by using both a reduced shift time and a low utilization rate understates capacity. Entering run time per hundred units instead of per unit overstates load by a hundred times. Using calendar days instead of factory calendar days overstates availability.

**Bullets:**

- Use factory calendar working days
- Check units on run time
- Remember to include rework and queue time separately

**Cta:** If you want capacity loads by work center and week pulled straight from your SAP orders, we can build a read only dashboard on your data, with the query visible.

**Faq:**

#### How does SAP calculate available capacity?

**Answer:** SAP multiplies operating time, the number of individual capacities and the capacity utilization rate. Operating time comes from the shift definition and factory calendar minus breaks. The result is the available capacity shown in capacity evaluation.

#### What load percent should I target?

**Answer:** There is no single number. Many plants plan below 100 percent to keep room for breakdowns and rush orders, often in the region of 80 to 90 percent. Your target depends on how stable your processes are.

#### Does this replace CM01 or CM02 in SAP?

**Answer:** No. It is a quick estimate for one work center. SAP capacity evaluation uses operation scheduling, formulas and real dates per order, so use it for the final view and leveling.

#### Why include setup time separately?

**Answer:** Setup is charged once per lot while run time scales with quantity. Separating them shows the effect of lot size. Larger lots reduce setup load but increase inventory and lead time.

## Search terms

sap capacity planning calculator, sap work center capacity load, sap cm01 cm02 capacity evaluation, work center available capacity formula, sap capacity utilization rate, sap capacity requirements setup run time, capacity load percent calculator

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