Two capacity constraints on a production line are the total quantity of parts that can be produced and the amount of time available to make those parts. When flow rates are used in a schedule, you can compare the sum of all scheduled orders to these two constraints.

You can associate target and maximum flow rates either with a production line or with a schedule code. The target rate is the optimal rate where production is the most efficient. The maximum rate is the absolute maximum rate that the production line can support.

As orders are entered into a schedule, the schedule order quantity is accumulated and compared to the schedule target and maximum. By viewing the percentage displayed before you actually add the schedule to the database, you can determine if the schedule exceeds the target or maximum.

See Physical Usage Data.

Production Quantities for Different Flow Rates shows three different flow rates for parts A, B, and C. Normal represents a typical level of production. NewMach represents typical labor usage plus the use of a new machine. MoreLbr represents the use of additional labor on a production line.

Assigning flow rate codes to items lets you evaluate the most effective use of time and machines for a particular schedule. Changing the flow rate code for an item may not automatically increase the production for that part. For example, the NewMach code has no affect on part B because it cannot be produced on that machine, and part C is totally constrained by machine capacities, so using the MoreLbr code has a minimal effect.

See Defining Flow Rate Codes.

In the following examples, the same schedule is used with different rate codes. The target rate for this production line is 500 units per 40 hour work week. The total scheduled orders are for 490 units, so the physical usage is 490 / 500, or 98%. There is enough physical capacity on this line to make the parts.

Using the Normal rate code, time usage is 49 / 40, or 122.5%. You would need to schedule 9 hours of overtime or handle the overcommitment of time in some other way. You could use a new machine and implement the NewMach rate code or you could add more operators and implement the MoreLbr rate code.

Implementing the NewMach rate code where an additional machine is used results in a time usage of 37 / 40, or 92.5%.

Implementing the MoreLbr rate code where more labor is used results in a time usage of 33 / 40, or 82.5%.

See Time Usage Data.