Production Capacity Planning Template

This capacity planning template provides a structured framework for calculating and comparing capacity across multiple dimensions. The **Resource Inventory** section lists all production resources (machines, lines, cells) with their theoretical capacity (units per hour), demonstrated capacity (actual average including OEE), number of available shifts, and working calendar. The **Demand Requirements** section captures the planned production orders by product and time period, with each product's required hours per unit (cycle time × quantity). The **Capacity vs. Demand Matrix** is the core analysis: a grid comparing available hours against required hours for each resource in each time period, with automatic overload and underload highlighting. The **What-If Scenarios** section models options for resolving capacity gaps: overtime hours, additional shifts, subcontracting, and demand redistribution. Summary dashboards show overall capacity utilization, bottleneck resources, and capacity projections for the planning horizon.

Begin by populating the resource inventory with current equipment and staffing data. Use demonstrated capacity (based on OEE or actual historical output) rather than theoretical nameplate capacity — scheduling against theoretical capacity guarantees overcommitment. Enter the demand forecast or firm orders for the planning horizon, broken down by product and time period (weekly or monthly). The template automatically calculates required capacity hours for each resource by multiplying demand quantities by per-unit processing times. Compare required vs. available capacity to identify overloads (red) and underloads (green). For overloaded resources, use the what-if section to evaluate resolution options: Can overtime close the gap? Is it more cost-effective to subcontract? Should demand be shifted to an earlier or later period? For underloaded resources, consider whether the slack can absorb future demand growth or whether staffing adjustments are warranted. Update the capacity plan monthly (or weekly for short-term planning) and use it as the foundation for your LinePlanner production calendar.

Beyond basic load-vs-capacity comparison, several advanced techniques improve planning accuracy. **Finite capacity scheduling** accounts for the sequence of orders at each resource, revealing that a resource may have sufficient total capacity but cannot process orders in the required sequence due to changeover constraints. **Mixed-model analysis** calculates capacity requirements based on the actual product mix rather than average product characteristics, which is essential when different products have significantly different cycle times. **Seasonal demand modeling** uses historical patterns to forecast demand peaks and plan capacity proactively — hiring temporary workers, pre-building inventory, or arranging subcontractor agreements before the peak arrives. **Bottleneck-focused planning** gives extra attention to the most constrained resource, since it determines system throughput. Pair this template with LinePlanner's visual calendar to translate capacity plans into actionable production schedules that respect the capacity constraints you have identified.