I have these orders to ship this month: do they fit? Paste the order book and the machines to see each resource’s load, the bottleneck and how much overtime, shifts, machines or outsourced hours you need, with the cost of each option.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Hours required as a % of hours available in the period; the line marks 100%.
For each resource above 100%: what each option requires, whether it fits the limits entered and what it costs in the period.
Hours required by each order at each resource, with the hours available.
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It compares the hours the order book requires at each machine with the hours each machine has in the period. It shows the bottleneck, how much is missing and the cheapest way to cover it: overtime, Saturdays, an extra shift, a machine or outsourcing.
For each order line: quantity ÷ (1 − scrap) × standard time ÷ efficiency, plus setup × number of batches. In the example the Machining center needs 364.6 h and has 315 h in the month (21 days × 2 shifts × 7.5 h), a 116% load.
Standard time: routing or time study, in minutes per part, without losses. Efficiency: the machine’s measured OEE, or parts made ÷ parts possible at standard time. Scrap: the rate quality records. Without data, 75% efficiency and 2% scrap are a conservative starting point for machining.
The Machining center is short 49.6 h. Overtime alone would take 2.36 h a day, above the 2-hour limit; four Saturdays would cover it. The cheapest option within the limits is shown with a check mark in the options table; the CNC lathe, at 80%, is still green but close to the warning limit.
There is no 100% in practice: breakdowns, shortages, rework and rush orders eat part of the time. Planning up to 80% to 85% of effective capacity usually keeps due dates. Above that, any surprise becomes a delay; below 50% there is idle capacity to sell.
No. It checks whether the load fits in the period (infinite capacity, no time sequence). To decide the order and timing of each job at the bottleneck, use the job sequencing calculator, which receives the orders of the most loaded resource.
It assumes the same efficiency for every product on a resource, identical machines, an operator whenever the machine runs and load spread over the period. It ignores due dates within the month, material shortages and queue time. Overtime cost applies the premium to labor only; check labor law and any union agreement before scheduling.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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