Work Center Capacity Definition
SyteLine CRP accuracy starts with correct work center definitions in the Work Center form (SL_Wc). Each work center must reflect realistic available capacity based on shift schedules, crew sizes, efficiency factors, and planned downtime. Overstated capacity produces optimistic CRP reports that mislead schedulers into overcommitting the shop floor.
- Available hours per work center calculated from shift calendar minus planned maintenance and breaks
- Efficiency factor applied to theoretical hours reflecting demonstrated output rate (typically 80-90%)
- Utilization factor distinguishing between total available time and productive time (accounting for changeovers)
- Crew size and machine count configured separately for work centers with operator-machine ratios
- Seasonal capacity adjustments for work centers affected by temporary labor or planned shutdowns
Routing-Based Load Calculation
CRP calculates resource load from routing operations on planned and released production orders. Each routing operation specifies setup time, run time per unit, and the assigned work center. SyteLine's CRP report aggregates these times across all orders to produce a load profile per work center per time period.
- Setup time and run time per piece on routing operations feeding CRP load calculations
- Overlap and offset percentages on sequential operations affecting the timing of load distribution
- Move time and queue time between operations spreading load across planning periods
- Alternate routing consideration when primary work center shows overload in CRP analysis
- CRP load displayed in SyteLine as hours or percentage of available capacity per planning bucket
Bottleneck Analysis and Capacity Balancing
CRP reports reveal bottleneck work centers where load consistently exceeds capacity. Bottleneck management is the highest-leverage scheduling activity because throughput of the entire production system is limited by its constraints. SyteLine's capacity load reports enable planners to focus on the critical few work centers that gate output.
- Bottleneck identification: work centers exceeding 90% capacity utilization for 3+ consecutive periods
- Load leveling by shifting planned orders to earlier or later periods within customer due date tolerance
- Overtime authorization process triggered when CRP shows bottleneck overload exceeding 110% capacity
- Subcontracting decision support when internal capacity cannot meet CRP-projected demand
- Weekly CRP review meeting focused on top 3-5 constraint work centers with action plans
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SyteLine Work Center Capacity Load Worksheet
Compare weekly available capacity with planned load by work center and spot overloaded and underused resources.
Identify and resolve your capacity bottlenecks in SyteLine -- our planning consultants configure CRP that works.