PRODUCTIVITY - FOCUSED CAPACITY PLANNING & LINE OPTIMIZATION

DAY 1: Establishing Capacity Visibility & Productivity Baseline

Module 1: Productivity & Capacity – The Strategic Connection

• Shift mindset from output chasing to capacity intelligence
• What productivity really means (Output vs Effort vs Flow)
• Why productivity problems are capacity problems
• Common myths in capacity planning
• Relationship between demand, takt time, and capacity
• Productivity losses hidden in planning assumptions
• Identify productivity symptoms vs true capacity issues in operations

Module 2: Understanding Capacity – Theory vs Reality

• Reveal the gap between planned and actual capacity
• Types of capacity:
  • Installed capacity
  • Available capacity
  • Effective capacity
  • Utilized capacity
• Planned vs unplanned losses
• Impact of downtime, changeover, quality, and absenteeism
• OEE as a capacity input (not just a KPI)
• Calculate effective capacity using a sample production line

Module 3: Capacity Calculation for Productivity Improvement

• Enable participants to compute true line capacity
• Capacity calculation formulas
• Cycle time vs takt time
• Manpower-based vs machine-based capacity
• Shift pattern and calendar impact
• Identifying capacity constraints using data

Module 4: Identifying Bottlenecks & Productivity Losses

• Make constraints visible
• What is a bottleneck (and what is not)
• Signs of hidden bottlenecks
• Work-in-process (WIP) as a bottleneck signal
• Constraint vs non-constraint process behavior
• Impact of imbalance on productivity
• Bottleneck identification using process flow data

DAY 2: Line Optimization & Capacity-Driven Productivity Gains

Module 5: Line Balancing for Productivity

• Improve output without adding resources
• Principles of line balancing
• Balancing vs leveling
• Task distribution and workload variation
• Balancing manpower-intensive lines
• Impact of balance loss on productivity

Module 6: Line Optimization Techniques

• Convert analysis into improvement actions
• Bottleneck exploitation techniques
• Non-bottleneck optimization (avoid overproduction)
• Changeover reduction impact on capacity
• Man-machine separation
• Parallelization and task redesign
• Simple layout improvements for flow

Module 7: Capacity Planning for Demand Variability

• Sustain productivity under changing demand
• Capacity buffers vs inventory buffers
• Flexible manpower planning
• Skill matrix and multi-skilling impact
• Scenario planning for demand changes
• Short-term vs medium-term capacity decisions

Module 8: Productivity Improvement Action Plan

• Translating analysis into action
• Prioritizing productivity improvement initiatives
• KPI alignment (Output, Utilization, Flow)
• Roles & responsibilities
• Monitoring and review cadence