Operations Management IMT

CAPACITY
PLANNING AND
MANAGEMENT
Chapter 8
f theres a downside to selling a product users
cant live without, its that customers tend to be

unforgiving when something goes wrong. Thats a
lesson BlackBerry maker Research In Motion (RIM)
Ltd., based in Waterloo, Ontario, learned in 2008
after the companys popular wireless email service
failed for about three hoursthe second largescale service disruption in less than a year
leaving so-called Crackberry addicts running for
their desktop computers to read messages.
Reports suggested the outage was related to RIMs
efforts to expand capacity at its central operating
Critics argue that RIM is more susceptible to major

service failures because of its centralized network
architecture. RIM designs servers that relay email
from a companys own server to a network
operating center, where it is then handed off to a
wireless carrier and beamed to a subscribers
device. The advantage of such a centralized setup
is that it gives RIM more control over the system
and its security, even during an interruption. The
downside, however, is that a major problem at the
operating center such as inadequate server and
backup capacity threatens to cascade throughout
the entire system, turning a localized issue into a
continent-wide mess.
What do you think?

Have you ever
experienced
problems with a
service because of
inadequate labor or
equipment
capacity?
Understanding Capacity
Capacity is the capability of a
manufacturing or service resource such
as a facility, process, workstation, or
piece of equipment to accomplish its
purpose over a specified time period.
Capacity is determined by the resources
available to the organizationfacilities,
equipment, and laborhow they are
organized, and their efficiency as determined
by specific work methods.
Capacity can be viewed in one of two ways:
1. As the maximum rate of output per unit of
time, or
2. As units of resource availability.
CHAPTER 10
CAPACITY MANAGEMENT
KEY CAPACITY ISSUES

Can the facility, process, or equipment
accommodate new goods and services and
adapt to changing demand for existing
goods and services?
How large should facility, process, or
equipment capacity be?
When should capacity changes take place?
OM3 Chapter 10 Capacity Management

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Exhibit A Examples of Short- and Long-Term Capacity Decisions
Solved Problem
An automobile transmission-assembly
factory normally operates two shifts per day,
five days per week. During each shift, 400
transmissions can be completed under ideal
conditions. What is the capacity of this
factory?
Capacity = (2 shifts/day)(5 days/week) X
(400 tranmissions/shift) X
(4 weeks/month)
= 16,000 transmissions/month
Economies of scale are achieved when
the average unit cost of a good or service
decreases as the capacity and/or volume
of throughput increases.
Diseconomies of scale occur when the
average unit cost of the good or service
begins to increase as the capacity and/or
volume of throughput increases.
A focused factory is a way to achieve
economies of scale without extensive
investments in facilities and capacity by
focusing on a narrow range of goods or
services, target market segments, and/or
dedicated processes to maximize
efficiency and effectiveness.
Capacity Measurement in Operations

Safety capacity (often called the
capacity cushion) is an amount of
capacity reserved for unanticipated events,
such as demand surges, materials
shortages, and equipment breakdowns.
Average safety capacity (%)
= 100% Average resource utilization %
[10.1]
Exhibit B The Demand versus Capacity Problem Structure
Capacity Measurement in Job Shops

In a job shop, setup time can be a
substantial part of total system capacity.
Capacity Required (Ci) = Setup Time (Si)
+ [Processing Time (Pi)
x Order Size (Qi)]
= Si + [(Pi)(Qi )]
[10.2]
Solved Problem
Exhibit C Dental Office Procedures and Times for Today
Solved Problem
Exhibit D Dental Office Demand-Capacity Analysis
*Example computation:
C = (Si + Pi Qi) = 15 + 15 + (90 2) = 210 minutes,
assuming
a setup for each patient.
Solved Problem
A total of 610 minutes of work are scheduled
during a 480-minute workday.
Capacity shortage of 130 minutes.
21.3% of capacity used to set up and change
over dental procedures.
If setup times could be reduced by 50%, the
capacity shortage would be only 65 minutes,
requiring only one hour of overtime.
Long-Term Capacity Strategies

Complementary goods and services
can be produced or delivered using the
same resources available to the firm, but
whose seasonal demand patterns are out
of phase with each other.
Complementary goods or services balance
seasonal demand cycles and therefore use
the excess capacity available (see Exhibit
E).
Exhibit E Seasonal Demand and Complementary Goods or Services

Capacity expansion strategies require
determining:
of
Amount
Timing
Form
capacity changes.

Four basic strategies:
1. One large capacity increase (Exhibit F.a).
2. Small capacity increases that match
average demand (Exhibit F.b).
3. Small capacity increases that lead demand
(Exhibit F.c).
4. Small capacity increases that lag demand
(Exhibit F.d).
Exhibit F Capacity Expansion Options
Short-Term Capacity Management

Adjust Short-Term Capacity Levels
Add or share equipment: Lease equipment as needed

or set up a partnership arrangement with capacity
sharing. (Examples: Mainframe computers, CAT
scanner, farm equipment)
Sell unused capacity: Sell idle capacity to outside
buyers and even competitors. (Examples: Computing
capacity, perishable hotel rooms)
Change labor capacity and schedules: Short-term
changes in work force levels. (Examples: Overtime,
extra shifts, temporary employees, outsourcing)
Change labor skill mix: Hire the right people; crosstraining.
Shift work to slack periods (Example: Build up
inventory during slack times and hold for peak demand
Short-Term Capacity Management

Shift and Stimulate Demand
Vary the price of goods or services (Examples:
Cheaper hotel rates on weekends; sales of
overstocks)
Provide customers with information (Example:
Automated messages with best times to call or
visit)
Advertising and promotion (Examples: Afterholiday sales, manufacturer or service coupons)
Add peripheral goods and/or services (Examples:
Movie theater rentals at off-peak times, extended
service hours)
Provide reservations: A promise to provide a
good or service at some future time and place.
CHAPTER 10
CAPACITY MANAGEMENT
SHORT TERM CAPACITY MANAGEMENT
Revenue Management Systems

A revenue management system (RMS)
consists of dynamic methods to forecast
demand, allocate perishable assets across
market segments, decide when to overbook
and by how much, and determine what price to
charge different customer (price) classes.
Examples: Managing overbooking in airlines,
hotels, and cruise lines (yield management).

27
Theory of Constraints
The Theory of Constraints (TOC) is a set of
principles that focuses on increasing total
process throughput by maximizing the
utilization of all bottleneck work activities and
workstations.
Throughput: Amount of money
generated per time period through actual
sales.
Constraint: Anything that limits an
organization from moving toward or
achieving its goal.
Theory of Constraints
A physical constraint is associated with
the capacity of a resource (e.g., machine,
employee).
A bottleneck work activity is one that
effectively limits capacity of the entire
process.
A nonbottleneck work activity is one in
which idle capacity exists.
A nonphysical constraint is
environmental or organizational (e.g., low
product demand or an inefficient
management policy or procedure).
Exhibit G Basic Principles of the Theory of Constraints
CHAPTER 10
CAPACITY MANAGEMENT
DAVID CHRISTOPHER, ORTHOPEDIC

SURGEON, CASE STUDY
1. What is the clinics current weekly
workload?
2. Should the clinic hire more surgeons, and if
so, how many?
3. What other options and changes could be
made to maximize patient throughput and
surgeries, and therefore revenue, yet not
comprise on the quality of medical care?
4. What are your final recommendations?
Explain your reasoning.
32

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CAPACITY

f theres a downside to selling a product users

cant live without, its that customers tend to be

Critics argue that RIM is more susceptible to major

What do you think?

KEY CAPACITY ISSUES

OM3 Chapter 10 Capacity Management

Exhibit A Examples of Short- and Long-Term Capacity Decisions

Capacity Measurement in Operations

Exhibit B The Demand versus Capacity Problem Structure

Capacity Measurement in Job Shops

Long-Term Capacity Strategies

Exhibit E Seasonal Demand and Complementary Goods or Services

Long-Term Capacity Strategies

Long-Term Capacity Strategies

Exhibit F Capacity Expansion Options

Short-Term Capacity Management

Add or share equipment: Lease equipment as needed

Short-Term Capacity Management

SHORT TERM CAPACITY MANAGEMENT

Revenue Management Systems

OM3 Chapter 10 Capacity Management

Exhibit G Basic Principles of the Theory of Constraints

DAVID CHRISTOPHER, ORTHOPEDIC

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