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Capacity Planning

Capacity Planning in PrismERP is a strategic function that helps manufacturing and production teams evaluate whether their resources (machines, labor, and work centers) are sufficient to meet forecasted or actual demand. It bridges the gap between production capabilities and customer orders or MRP-generated schedules to ensure on-time delivery and optimal resource utilization.

Key Features​

  • Real-Time Capacity Analysis — View available vs. required capacity by date, work center, or shift.
  • Work Center & Shift-Based Planning — Allocate capacities based on individual work centers and shift timings.
  • Dynamic Load Balancing — Suggest work redistribution to underutilized machines or lines.
  • Integration with MRP & Production Orders — Auto-calculate capacity needs from planned production.
  • Overload Notifications — Get alerts when planned load exceeds available capacity.
  • Simulation Tools — Test “what-if” scenarios for adding shifts, changing routings, or rescheduling orders.
  • Visual Calendars & Gantt Charts — Intuitive UI for planners to make adjustments quickly.
  • Backward & Forward Scheduling Options — Choose based on production policy or delivery deadlines.

Key Benefits​

  • Optimized Resource Utilization — Prevent bottlenecks and reduce idle time.
  • Improved On-Time Delivery — Align production capabilities with delivery commitments.
  • Reduced Overtime & Costs — Better planning leads to lower emergency labor and overtime.
  • Increased Flexibility — Easily adapt to demand fluctuations or machine downtimes.
  • Data-Driven Decision Making — Informed scheduling based on historical and real-time capacity data.

Usage Guide in PrismERP​

Setup Work Centers & Shifts​

Navigate to Work Center Configuration Define work centers with shift patterns, available hours, absenteeism %, and machine efficiency.

Define Capacity Parameters​

Go to Define Parameters Assign standard hours, productivity ratios, and other configurations.

Review Capacity Load​

Go to: Capacity Planning Dashboard Filter by date, branch, unit, work center, or shift. View available vs. required capacity.

Analyze Overloads​

System highlights overloaded work centers in red. Click on the load bar to view the production orders contributing to the load.

Take Action​

Reassign orders to alternate work centers with spare capacity. Modify shift timings or increase machine hours if required.

Generate Reports​

Use standard reports: Capacity vs. Load Report, Work Center Utilization, Backlog Summary.