SyteLine Work Center Capacity and Load Worksheet
Before you promise dates, you need to know whether the work centers can absorb the load. This worksheet turns shifts, machines and efficiency into weekly capacity and compares it with planned hours.
| Work center | Machines or stations | Hours per shift (hrs) | Shifts per day | Days per week | Efficiency (%) | Planned load (hrs) | Capacity (hrs/wk) | Utilization | Headroom (hrs) | |
|---|---|---|---|---|---|---|---|---|---|---|
246 | 219.5% | -294 | ||||||||
191.25 | 172.5% | -138.75 | ||||||||
67.5 | 118.5% | -12.5 | ||||||||
38 | 94.7% | 2 | ||||||||
180 | 88.9% | 20 |
Enter planned load from a capacity requirements report or your open job routings for the week. Over 100% means the work center is overloaded; below about 70% suggests slack.
Live capacity dashboard
Optional: ask how weekly load by work center could be shown from your own SyteLine data.
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How to use the worksheet
Add a row per work center. Enter the number of machines or stations, productive hours per shift, shifts per day, days per week and efficiency. Enter planned load in hours for the week from your open jobs or an MRP generated capacity report. Capacity, utilization and headroom calculate automatically. Edit the sample rows or delete them, then export to Excel to share with production meetings.
- Use net hours after breaks and planned maintenance
- Use the same work center names as in your routings
- Build one sheet per week or per planning bucket
Formulas
Capacity equals machines times hours per shift times shifts per day times days per week times efficiency. Utilization equals planned load divided by capacity. Headroom is capacity minus load. Overall utilization uses the totals so a lightly used assembly area does not hide an overloaded milling cell. A bottleneck is the work center with the highest utilization, and it sets the throughput of the whole plant.
Reading the results
Treat utilization over 85 to 90% as risky in a job shop, because queues grow rapidly as utilization approaches 100%. Overloaded centers call for overtime, outsourcing, rerouting to another machine or moving due dates. Underused centers may be a sign that the bottleneck is upstream. Remember that infinite capacity MRP does not detect these overloads, so a finite schedule or this review is the safeguard.
- Check load includes setup as well as run hours
- Consider alternate work centers for overflow
- Review weekly, not only at month end
Frequently Asked Questions
Where do I get planned load?
From open job operations with remaining setup and run hours by work center, or from a capacity requirements report. Sum them per week for the periods you plan.
What efficiency should I use?
Use observed efficiency from reported labor or machine hours against standard. Many shops sit between 70 and 90 percent. Avoid using 100 percent.
Why do I get a very high utilization?
Check units: load and capacity must both be in hours for the same period. Also confirm that machines and shift counts are entered correctly.
Does this replace finite scheduling?
No. It is a quick check of aggregate capacity. Finite scheduling or APS sequences jobs and considers calendars and constraints in detail.
If you would like weekly work center load pulled automatically from SyteLine jobs and presented as a live dashboard, we can build that.
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