Capacity & Production Balancer
Model daily and annual capacity, define fixed and variable capabilities, prioritise limiting factors and allocate compatible jobs to workplaces.
Purpose and method
Assess finite capacity and optimize job assignment using fixed workplace capabilities and automatically assigned variable equipment.
When to use it
Use the balancer when workplaces have different fixed capabilities while pins, feeders, fixtures or tools can be exchanged. The optimizer selects a workplace and proposes the required variable equipment.
Core principle
Capacity is feasible only when time and technical capability are both satisfied. Aggregate free minutes cannot compensate for a missing process, current, tooling or qualification constraint.
What the interactive module provides
- Annual and peak-day capacity verdict
- Optimized machine, job and variable-equipment allocation
- Bottlenecks, compatibility matrix and branded PDF report
- compatible allocation, daily/annual utilisation, bottlenecks, variable setup plan and unassigned-job reasons
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
01
Recommended workflow
Model daily and annual capacity, define fixed and variable capabilities, prioritise limiting factors and allocate compatible jobs to workplaces.
- 1
Define net calendar and capacity assumptions
- 2
Describe every workplace capability explicitly
- 3
Describe each job requirement and demand
- 4
Set priorities and run capability-aware allocation
- 5
Review unassigned jobs and validate the operating plan
02
Practical example
Total annual capacity appears sufficient, but two jobs require a 16 kA source and M10 tooling available at one station only. Capability-aware allocation exposes that station as the real constraint.
Calculation or verification principle
Net daily time = shifts × (shift length − breaks). Job load = annual demand × cycle time ÷ working days. Utilisation = required time ÷ available compatible time × 100%.
Required inputs → Expected outputs
- Required inputs
- workplaces, shifts, breaks, working days, fixed/variable capabilities, priorities, jobs, cycle times and demand
- Expected outputs
- compatible allocation, daily/annual utilisation, bottlenecks, variable setup plan and unassigned-job reasons
03
Common mistakes to avoid
×
Entering shift length net of breaks and subtracting breaks again
×
Treating all machines as technically interchangeable
×
Using annual totals while ignoring daily peaks and changeovers
×
Forcing allocation despite unmatched capability
04
Frequently asked questions
What data do I need to use this tool?
Prepare workplaces, shifts, breaks, working days, fixed/variable capabilities, priorities, jobs, cycle times and demand.
What result does the module produce?
The module produces compatible allocation, daily/annual utilisation, bottlenecks, variable setup plan and unassigned-job reasons.
Can I implement the result without further review?
No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.
LEAN Toolbox
Open interactive tool →Capacity & Production Balancer
Model daily and annual capacity, define fixed and variable capabilities, prioritise limiting factors and allocate compatible jobs to workplaces.