Capacity Constraint Analyzer
Overview
The Capacity Constraint Analyzer provides production and supply chain capacity analysis using Theory of Constraints (TOC) principles. It identifies bottlenecks, models capacity exploitation strategies, and supports capacity investment decisions.
Capabilities
- Capacity Utilization Calculation: Resource utilization analysis
- Bottleneck Identification: Constraint and limiting factor detection
- Constraint Exploitation Strategies: TOC-based improvement approaches
- Capacity Adjustment Modeling: Expansion and contraction scenarios
- Lead Time Impact Analysis: Capacity effects on delivery performance
- Rough-Cut Capacity Planning: Aggregate capacity assessment
- Finite Capacity Scheduling Support: Detailed scheduling inputs
- Capacity Investment Analysis: CapEx decision support
Input Schema
capacity_analysis_request:
resources:
work_centers: array
- resource_id: string
name: string
available_capacity: float
capacity_unit: string
efficiency: float
setup_time: float
labor: array
equipment: array
demand_requirements:
production_plan: array
capacity_requirements: array
- resource_id: string
product: string
rate: float
constraints:
operating_hours: object
maintenance_windows: array
policy_limits: object
analysis_parameters:
time_horizon: string
granularity: string
scenarios: array
Output Schema
capacity_analysis_output:
utilization_analysis:
by_resource: array
- resource_id: string
name: string
available_capacity: float
required_capacity: float
utilization_percent: float
status: string # under, balanced, constrained, over
summary: object
bottleneck_identification:
constraints: array
- resource_id: string
constraint_type: string
impact: string
root_cause: string
constraint_ranking: array
exploitation_strategies:
recommendations: array
- strategy: string
target_resource: string
expected_improvement: float
implementation_effort: string
capacity_scenarios:
scenarios: array
- scenario_name: string
capacity_changes: object
cost: float
benefit: float
lead_time_impact: string
investment_analysis:
options: array
npv_comparison: object
payback_analysis: object
rough_cut_capacity_plan: object
Usage
Bottleneck Identification
Input: Production plan, resource capacities
Process: Calculate utilization, identify constraints
Output: Bottleneck report with ranking
Capacity Scenario Analysis
Input: Demand growth scenarios, current capacity
Process: Model capacity options and impacts
Output: Capacity scenario comparison
TOC Exploitation Strategy
Input: Identified constraint, current operations
Process: Apply TOC principles for exploitation
Output: Constraint exploitation recommendations
Integration Points
- ERP/MES Systems: Capacity and production data
- Planning Systems: Demand and production plans
- Scheduling Systems: Finite capacity scheduling
- Tools/Libraries: Theory of Constraints frameworks, scheduling algorithms
Process Dependencies
- Capacity Planning and Constraint Management
- Sales and Operations Planning (S&OP)
- Supply Chain Network Design
Best Practices
- Validate capacity data accuracy
- Consider all constraint types (physical, policy, market)
- Focus improvement efforts on true constraints
- Model multiple demand scenarios
- Include maintenance in capacity calculations
- Review capacity plans monthly