rough cut capacity planning
TRANSCRIPT
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Agenda▪ Capacity Planning Overview
▪ Intermediate Process
▪ Capacity Planning Tool
▪ Maintenance & Project Tracking
▪ Summary
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✓ Request
✓ Initiate
✓ Capacity
✓ Demand
✓ Cycle Time
✓ Planned Capacity
✓ Resource Chart
✓ Stoplight chart
✓ Action Plans
✓ Align Parts
✓ CAF Steps
✓ Alerts
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Benefits of tools for Suppliers & Caterpillar
Supplier
• Improved performance
• Lowered operations cost
• Balancing load
Caterpillar
• Executable build plan
• Supports enterprise S&OP
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Key Definitions• Burden
• The amount of required capacity in order to meet demand
• Capacity
• The capability of a worker, machine, work center, plant, or organization to produce output per time period, independent of burden
• Routings
• Which parts go through which resources? This is an essential piece of information for completing RCCP (forward looking) charts, as it helps determine the quantity of parts going across a resource
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Outcomes
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RCCP Chart (Resource Chart)
• Forward looking, 18 months
• For processes that appear constrained based on burden chart
• May be required for all processes, if other groups using the RCCP (e.g., certain sourcing councils) require it
• Requires part routings to complete
Burden Chart
•End-to-end current state view of burden vs. capacity for processes across which Caterpillar parts run
•Which areas appear constrained (>80% burdened)?
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Intermediate RCCP Process Overview
Supplier
Information
Capacity Data
Collection
Initiate RCCP
Project in DVT
Pre-workSupplier
Input
Analysis &
Report OutMaintenance
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Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14
H
o
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Month
RCCP Chart (Hours)
CAT Demand CAT Past Dues Demonstrated Capacity for CAT Maximum Capacity for CAT Planned Capacity for CAT
Burden ChartMaintain iRCCP
Resource Charts for
Constrained, or All
Resources
Supplier
Onboarding
RCCP Request
Caterpillar/Supplier
Request to
Open/Refresh RCCP
Project in DVT
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Step 1- RCCP Request
https://demandvisibility.cat.com/DemandVisibilityTool/index.do
1. Go To Chrome Browser (preferably)
- Enter the following Link:
2. Input CWS id and password > Agree to terms 3. For access please contact:
Need for RCCP Coverage
• 2 Types of Request :Open New project
or Refresh a previous one.
• Any External supplier or Caterpillar
person with access to Caterpillar
Capacity Tool (DVT) can request an
RCCP project.
• Requestor should assign at least one
Caterpillar contact and could also assign
a supplier contact if desired.
• A notification email will be sent to
selected contacts and previous RCCP
owner.
Key Points
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1. Input supplier code linked to the
project (up to 3)
2. Create new intermediate per
selection
3. Select RCCP Area:
DEFAULT: One single RCCP
area
OTHER: Use to differentiate
an additional RCCP area
4. If you select OTHER, provide a 3
digit name for this area
5. Create project
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5Supplier area is a user defined field that identifies
separate work areas under the same supplier code
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Request RCCP- New Project
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1. Input supplier code linked to the project (up
to 3)
2. You get a view of previous project, when it
was last updated and by whom
Now you have 2 options:
1. Create New: All the information from
predecessor Project Will be copied (Supplier
codes, RCCP area configuration)
2. Create New Intermediate Per Selection: This
allows you to change original configuration,
add or remove supplier codes or rename
RCCP area.
- Select RCCP Area:
DEFAULT: One single RCCP area
OTHER: Use to differentiate an additional
RCCP area
-If you select OTHER, provide a 3
digit name for this area
- Create project
Request RCCP Project Refresh
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Request Tab
After Save as Request
Email will be sent to all
contacts within the
project
Supplier contact
is optional
If you are the RCCP owner you
may skip request and Initiate
Caterpillar contact can choose to
cancel the request
Must provide a
Caterpillar contact that
will be the RCCP
owner (Initiator).
For refreshed
projects, system
will bring previous
RCCP owner
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Step 2- Pre-workExplain supplier the need and level of detail we require for RCCP
•Supplier buy in and support before asking
for data
•Communicate value to both Supplier and
Caterpillar in doing RCCP
•Supplier will receive a notification that
RCCP project has initiated and the link to
Capacity site
•Keep all interested parties (supplier,
manager, buyer) informed
Key Points
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1. Date supplier was contacted
2. Select Cycle Time Type
• Actual (specific to each part) – this
will give the most accurate analysis
• Average – meets requirements for
coverage, but least accurate
• Weighted average – i.e., an average
where part mix is incorporated
3. Select Part Routing Type:
• Constraint Process only
• All process routing
4. Use Build Index?
• YES - 6 Months of EDI and the
remaining 12 are extrapolated from
Demand INDEX
• NO – Provides 18 months of
available EDI signal
5. Search Supplier contact
6. Select auto initiate period from dropdown
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Initiate screen can ONLY be input by a Caterpillar
person which will be the RCCP owner of the project
Initiate Tab
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RCCP Level of Information
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Escalation Ready
• For burden calculation use
demand from demand tab x
cycle times for each part
• All part routings & cycle times
must be provided
• Actual cycle are required
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Step 3 – Supplier InputData Collection
• There are 2 input data options: Manual
and Upload from Template
• For a refreshed project, download
template will bring previous project data
• For a successful upload make sure you
follow format recommendations on the
upload screen
• All fields need to be filled for Save option
to be enabled
• On each tab make sure you Save your
data before moving to a different tab,
otherwise your information will be lost
Key Points
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Capacity Tab1. Resource: All areas / Machines in facility that are used for the
production of Caterpillar parts.- Character Restricted
2. Resource Description: Complete resource name.
3. Process represented by area
4. Constrained By: choose whether the process is constrained by
labor or machine
5. Demand Unit of Measure: This Can be Pc parts/Tons or Hours
6. Run Rate Type: Actual/Planned
7. Run Rate: Indicate the average capacity rate (planned or actual)
per hour per resource. This can be pieces per hour, or tons per
hour
8. Total Average Weekly Demand on all Resources: Make sure it
aligns to selected unit of measure (5)
9. CAT Average Weekly Demand: (Caterpillar Tier 1 only)
10. CAT Load %: % of CAT load on that area (time consumed not qty)
11. Past Dues: Indicate the amount of current past dues for each
work area. Note that these are internal past dues
12. Caterpillar Past Dues: indicate the amount of internal past dues
per resource that are Caterpillar parts
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Capacity Tab
13. Cur # of Resources: Specify the number of resources that are
currently being used in production
14. Max Resources: Specify the maximum amount of resources that
could be used in production
15. Cur Hours per Shift: Indicate the production hours per shift. Do not
include any break time
16. Max Hours per Shift: Include the maximum amount of production
time possible
17. Cur # of Shifts Assigned
18. Max # of Shifts
19. Cur # of Days per Month: Indicate the current number of days per
month that each resource is in production
20. Max Days Work: Identify the maximum amount of days per month
that supplier can work for each resource/machine area
21. OEE %: Indicate the overall equipment effectiveness(OEE) in %.
EX 100%
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Auto populated field
Cycle Times UoM. Depending of user selection at Demand UoM
the system Will define the cycle time UoM that is required at Cycle
times page.
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1-3 – Resource, Description and Process
Resource Description• Longer resource name
Process
• For every machine area in supplier’s facility,
identify the process corresponding to the area
Resource
• Identify resource that produces ANY Cat parts (does
not have to be dedicated)
• Machines with similar part routings and cycle times
can be listed as a single line item with the number of
machines noted in the Number of resources field (13)
Examples:
• Work center consists of 3 different machines that
perform different operations, handle different parts,
or have very different cycle times: Each machine
needs to be listed separately
• If a weld station has 2 identical weld machines, list
“weld” as one machine area and adjust the number of
resources
Resource field is format restricted, 3 to 20 characters
no spaces or special characters allowed.
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4 – Constrained by Labor or Machine
Select the constraint type: Labor or Machine
• Could the resource produce more parts
with double the labor? Ex: Welding
operation (labor constraint) vs. Machining
center (resource constraint)
• This determines if labor or machines should
be used to determine number of resources
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5 – Demand Unit of Measure
• Use the drop-down box to indicate if demand is
given in pieces, tons or burden hours
• Depending of user input at Demand UoM the
system will define the unit of measure cycle
times need to be entered in at Cycle times page.
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6 & 7 – Run Rate Type & Run Rate
Run Rate Type
Actual Capacity Rate (demonstrated historically)
• Find the actual number of pieces produced per hour at each machine
• The purpose is to find the average hourly exit rate at each machine
Planned Capacity Rate:
• Planned average number of pieces produced per hour across a single
resource in a machine area
Run Rate
Indicate the average capacity rate (planned or actual) per hour per resource. This
can be pieces per hour, or tons per hour
When Demand UoM is Hours consider the following:
• On manual input Actual and planned capacity rate will turn gray and default to “1” if
total average weekly demand is entered in burden hours as capacity rate is
already included in burden hour calculation.
• On Uploading from template, all fields must be filled for successful upload. For
Run Rate Type, planned or actual need to be typed in and Run Rate needs to be “1”
Only needed if demand is given in Piece Parts/Tons
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8 & 9 – Total Average Weekly Demand on all ResourcesAverage CAT Weekly Demand
Average weekly demand should be forward looking, roughly a month or two :
This is the amount of burden shown in the Burden Chart (non escalation ready)
• Supplier must verify demand data based on their production
schedules
Total Average Weekly Demand : Specify total average weekly demand for
both Cat and non-Cat parts across all resources for that machine/resource
area
CAT Average Weekly Demand : One aggregate total average weekly demand
number for CAT Tier-1 demand across all resources in a machine area
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10 – CAT Load %
Indicate the percentage of load that Caterpillar parts take up on that
machine/resource area.
• If the machine/resource is dedicated to Cat, the CAT Load is
100%.
• If the machine/resource is shared, what % of scheduled
production TIME is spent making Cat parts. This may be different
than the percentage of parts that are Caterpillar.
• Some suppliers will have a contractual obligation or limit set of
the percent of capacity dedicated to Cat. If this is the case, type
in that percentage.
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Past Dues should be noted in the same units as your Total Average Weekly Demand/Total
Average Weekly CAT Demand
• Past dues are internal past dues, from machine to next process. These are not
past dues in terms of shipping to a Cat or Tier 2 facility.
Total Past Dues: For each resource, find out how many pieces/hours (CAT & Non-CAT) are
past due as of today
• Used to calculate the additional percent of burden that will be added by past
dues
Caterpillar Past Dues: For each resource, find out how many of the total pieces/hours past
due today are Caterpillar parts
• It is helpful, however, to know the number of CAT past dues to develop action
plans to alleviate any issues.
11 & 12 – Total Past Dues & Caterpillar Past Dues
• Past dues are a current snap shot in time regardless of the
duration over which they were accumulated
• Past dues burden the operation they are incurred on, not the
next operation they flow to..
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Parts produced should be largely interchangeable
across all resources if listed on the same line item
13 & 14 – Cur Number of Resources & Max ResourcesCur Number of Resources
• For a given process, identify number of separate resources(man or machines)
that are currently being used to perform the same operations
• Resources can be combined if part routings and cycle times are similar for the
resources in question
Max Resources
For a given process, identify maximum number of separate resources (man
or machines) available to be used to perform the same operations
Example:
There is currently 2 laser cutter allocated to this area, however the supplier
has the ability to use use the 4 laser cutters installed if necessary
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15 – 20: Operating ScheduleCur
Ener the total number of shifts per day, hours per shift that each
machine is currently scheduled to run (production time), and the
number of working days per month.
Max
Input the total number of shifts per day, hours per shift that each
resource could get scheduled to run (production time) and the
number of days per month at Max capacity.
12 Month Working Days:
Instead of average, you can now enter actual working days at each
month, removing any holidays or planned shut downs. This will
provide a more accurate Capacity view. When entering data in hours per shift
columns, only enter scheduled production
time which would not include
breaks/lunches
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15 – 20: Operating ScheduleThe information for the operating schedule all gets
multiplied together to determine the total hours for the
burden chart
• This means that the hours per day is (Number of
Resources)*(OEE or Operating Efficiency)*(Hours per
Shift)*(Shifts Per Day)*Number of days
Having Hrs. per Shift x Number of Shifts (Cur/Max) > 24
represents over 24 hours per day.
On Manual Input fields will highlight red and on
Uploading form template file will throw an upload error.Upload Error
Manual Input
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When filling out the Capacity Tab in Piece Parts…
If actual exit rates are available (historic demonstrated), then use
actual rates and not planned exit rates and ensure OEE defaults to
100%. In this case, it is 100% because time required to produce actual
output will capture process inefficiencies.
21 – OEE: Overall Equipment Effectiveness• OEE is used to find out overall effectiveness of each machine to
produce parts by factoring out losses
• Inefficiencies are tied to a machine area that result in a combination
of loss of availability, productivity, and/or first time yield for that area
• The calculation for the input to this field will vary depending on the
availability of historical performance metrics
The following slides will
break from the process to
provide more detail on OEE
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What is OEE?
• OEE stands for Overall Equipment Effectiveness
• OEE is a measurement that defines
• Percentage time a machine was actually producing quality parts compared to the time it was planned to be producing quality parts
• Equipment’s actual productivity compared to the ideal productivity, during a specified period of time
• The difference between actual performance and ideal performance is identified as waste, which must be eliminated. “What gets measured, gets done!”
• The main difference between OEE and Operating Efficiency is while OEE measures waste with allocated buckets, which allows for identification and systematic elimination of waste “Operating Efficiency” is just an approximation of overall waste.
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OEE = Availability x Performance x Quality
• Planned Production Time: Total time the equipment is scheduled for production. It is the Total Available Time minus Unscheduled Time.
• Actual Running Time: Total time the equipment actually ran during the production time. Actual Running Time removes any downtime losses including, but not limited to:• Breakdown or Equipment Fault• Setup/Adjustment• Operations team member missing (absent, personal time, lunch, meeting, training, 5S activities, etc..)• Material Missing (parts, tools, fixtures, gauges, etc..)• Startup Loss (time spent for startup to reach the right operating conditions, for example heating a furnace)• Quality/Inspection• Tool Change (piece of equipment stopped for a tool change)
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Availability = Actual Running Time / Planned production Time
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OEE = Availability x Performance x Quality
▪ Planned Method Time: Is calculated by multiplying the normal cycle time or theoretical time to produce one part times the total of all produced parts including defects
▪ Actual Running Time: Total time the equipment actually ran during the production time
▪ Performance should never be greater than 100%. If it is, that usually indicates that normal Cycle Time is set incorrectly (it istoo high).
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Performance = Planned Method Time / Actual Running Time
Note: If the Actual Running Time is continually over or under the Normal Cycle Time, the issue
needs to be investigated. If the Normal Cycle Time is believed to be incorrect, then the issue
needs to be fed back to the planning department for review.
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OEE = Availability x Performance x Quality
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• Bad Output: The amount of scrap and/or rework produced during the set-up and Actual
Running Time. As with good output, it is measured in pieces, feet, inches, pounds, etc..
• Actual Output: The total amount of output, good and bad produced during the set-up and
Actual Running Time, also measured in the same units, pieces, feet, inches, pounds, etc..
• Good Output: The amount of good, sellable output that was produced during the set-up and
Actual Running Time, where output could be pieces, feet, inches, pounds, or other depending
on the operation.
Calculated : Actual Output – Bad Output
Quality = Good output / Actual Output
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Capacity Tab - Manual Input
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For refreshed
projects update
demand and
operating schedule
per resource
Save or Delete
resource as needed
For each resource
fill all data boxes? Check out
available tooltips
Hit +New to add a
resource
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Capacity Tab - Upload From Template
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1. Download template
(RCCP_Capacity)
2. Fill in information following format
rules & Save
3. Choose file to upload
• To delete a resource you need to go to
detail tab, you can not remove from
template.
• To rename a resource do it from detail
screen to avoid same resource
recorded twice.
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Key Format Rules
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• Only Notes column can be left blank
• Resource Name: Name should be from 3 to 20 characters, no
spaces, no special characters
• Unit of measure allowed values: "Hours", "Pieces", "Tons"
• For unit of measure = “Hours” :
Run Rate Type = “Planned or Actual”
Run Rate = “1” (0 is not allowed)
• Number of shifts x Hours per shift can not be higher that 24
hours
• % OEE and Cat load expressed in format of 0 to 1
• If no Past dues value must be “0”
• On escalation ready : Average weekly demand still needs a
value, input can be 0Upload Success
Upload Error
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Demonstrated Capacity is normalized to 100% for all
machine areas.
Trigger for Capacity Planning: Any machine area at or
above 80% Capacity should be selected as a constraint
for Capacity Planning. If no machine areas are at 80%,
select the most burdened area.
At times, capacity planning may be required for all areas.
This is done at the discretion of other groups that may
use the results of this iRCCP. Minimum standards for
“coverage” are for all processes more than 80%
burdened, or the most constrained process.
WHY? We want to
extrapolate demand on the
constrained resource out
18 months and compare
Caterpillar demand against
the constrained area’s
capacity to ensure an
executable build schedule.
• Burden bars are created from the Total Average Weekly Demand on all
Resources provided at Capacity Tab. It tells us the average overall burden,
CAT & Non-CAT, on a given resource looking forward 4-6 weeks. The burden
chart is a snapshot in time of current burden on the machine areas listed on
the X-axis.
Reading The Burden Chart – Non Escalation Ready
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Parts Tab contains a list of all parts with demand for the
supplier code selection.
There are 3 main functionalities for this page:
1. Supplier Local part storage: Supplier can enter their
own local part number and save that relationship with
Caterpillar part, this for future reference at Cycle times.
2. Part Exclusion : User can select a list of parts that do
not need to be considered within project's scope.
Parts Excluded Will not be displayed at Demand tab.
3. Review the number of resources each part is tied to at
cycle times.
If user does not need to exclude or save local parts, they
can skip this step and go Next.
Parts Tab
If a part is missing cycle time, "Resources
with part" Will display blank
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Parts Tab - Manual Input
A part can not be excluded if it is linked to
at least one resource.
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Option 1
1. To exclude a Part:
• Check the Exclude box of the
respective part
• Provide a reason to Exclude by
selecting from drop down.
2. Part Numbers (From Supplier)
• Type the local part number related to
the respective Cat Part
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Parts Tab - Upload From TemplateOption 2
• Hit Download parts button
• Fill template according with format rules
1. Exclude: true = part excluded ; false = part not
excluded
2. Reason To Exclude : NPI , Pass-through Part
3. Part Numbers (From Supplier) : Enter supplier
local part for each Caterpillar part.
Note: Resources with part column is not an editable
field.
• Save All_Parts file to your local drive
• Hit Upload parts
• Choose file and Upload
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A part can not be excluded if it
is linked to at least one
resource.
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Demand Tab• System generated (Capacity tool pulls
information on a daily basis from MRC, SCDW
and CLIDB)
• Depending on selection at initiate screen system
will bring EDI & DEM INDEX or just EDI for 18
month scope.
• Supplier can add Manual demand (Tier 2).
• Upload/download feature for manual demand
available.
• Refresh Button will pull most recent EDI.
• Parts Excluded at parts page will not be
displayed at demand tab
Demand Index Selected on Initiate Screen
18 Months of EDI
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CASH / LIVE / REFRESH
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When a project is in progress
Cached • Capacity tool will take a snapshot of EDI /DEMAND INDEX of that moment in time when user got into demand tab.
• If the Project is not completed within the next few days and user wants to have an updated view just hit Refresh
System will ask confirmation before it refreshes data.
• Once it has been refreshed you can not go back to original data. New information has been Cached
• RCCP CHART/ DEMAND/ STOPLIGHT CHART show this refresh option.
• Live will be disabled at this point.
Refresh
Cached • Anyone with access to the approved project has 2 view options Cached and Live. They can switch back and forth
on this view.
• Live is the default view when opening an approved Project.
• Cached will show demand as it was originally submitted and Live is the EDI/ INDEX update for the day.
• RCCP CHART/ DEMAND/ STOPLIGHT CHART has these view options.
• Refresh button is disabled at this point.
When project has been Approved:
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Manual Demand - Manual Input
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• Purpose is to capture Tier 2 parts on capacity analysis
• On demand refresh if manual part# & facility combination is not
included on new EDI, tool will keep manual demand numbers
Option 1
• Hit add demand icon
• New row will show- Forecast Type Manual
• Select receiving facility from drop down
• Type PN & month over month forecast
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Option 2
• Hit Download manual demand for uploading button
• Fill template according with format rules
• Save Demand_Upload file to your local drive
• Hit Upload Manual Demand
• Choose file and Upload
Manual Demand – Upload From Template
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Filters
Each column within the Demand
tab can be filtered per user needs
Demand – Additional FeaturesDownload demand
• 18 Months of demand can
be downloaded to excel
• Option available for
Cashed and Live views
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Cycle Times Tab - Manual Input1. Pick a constraint from the left
2. Review auto defined Unit of measure and make
sure values entered are aligned
3. Identify ALL Caterpillar Tier 1 part numbers that
are routed across the identified constraint and
type each at part number rows
4. Identify actual/average cycle times (or Tons) for
each part number that pass through the
constraint
5. Repeat for all constrained areas identified in
burden chart – or ALL areas if Escalation ready
• For Cycle time, blanks and zero values are not allowed.
• On Escalation Ready user must provide part routings and cycle times for ALL parts and ALL
processes, Next button will not enable until all parts are included in at least one resource.
• On Non Escalation Ready user must provide part routings and cycle times for all constrained
process
• Local part number will be automatically pulled from Parts page.
• If a part needs to be excluded from analysis this Will have to be documented at parts page
with a reason for exclusion. Cycle times can not be entered for excluded parts
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Cycle Times Tab - Upload From Template
• All resources can be captured in a
single file
• For Cycle time blanks and zero
values are not allowed.
• Parts excluded can not have cycle
times
• Hit Upload Cycle Times button
• Hit Download Cycle Times button
• Fill template according with format rules
• Save RCCP_Cycle_Time file to your local drive
• Hit Choose File
• Choose file and Upload
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Key Format Rules
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• All fields must have a value, no blanks allowed
• Resource Name should exist in the capacity tab
• Unit of Measure allowed values:
“CycleTimeMins” , "Pieces" or “Tons” No spaces
Consider this value is already defined by system,. Using a
different unit of measure than the auto defined one Will
generate an upload error.
• Part Number same part can only exist once per resource
• Cycle time needs to be greater than 0
• Parts excluded can not have cycle times Upload Success
Upload Error
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Step 4 – Analysis & Report OutResource Chart and Action Plans
• For each constrained process, resource
chart will show 18 months outlook of
capacity vs demand
• For any capacity gap, action plan needs
to be captured
• Planned capacity is used to reflect action
plan and validate if proposed plan will
meet demand
• Burden Chart on resource tab is based
of EDI x Cycle times (Hrs.)
Key Points
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Resource Chart Components
CAPACITY BURDEN
Operating
Schedule
Supplier Provided
Data
Number of
Resources
Demand Index
EDI
System Generated
Data
Part Numbers
Cycle Times
(avg or actual) &
Routings
OEE or Efficiency
Factor
CAT Load%
Manual Demand
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Interpreting the Resource Chart
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There are three different capacity definitions for a machine area/resource
shown in an RCCP chart: Demonstrated, Planned, and Maximum. Each
definition of capacity is visually represented by a line in the RCCP chart.
Demonstrated Capacity is created by combination of:
•OEE, Hrs. per shift, # shifts assigned, # of Days per month, # of resources, %
Cat Load
Max Capacity is created by combination of:
•OEE, Max Hrs. per shift, Max # shifts assigned, Max Days Work for the month,
Max # of resources, % Cat Load
Planned Capacity deviates from Demonstrated if the RCCP Chart shows that
burden is greater than demonstrated capacity. Action plans should be
developed & reflected in the planned line.
Burden Bars are built from the cycle times/part routings & Demand (Demand
Tab). Each color represent the portion of burden per Cat receiving location
CAT% Load is also factored into the capacity definitions of that machine
area/resource. The lines in the RCCP charts are discounted to reflect
actual % of total capacity allocated to Caterpillar.
Each machine area/resource listed in the Capacity
Tab can be modeled with Capacity Planning if we
have routings and cycle times for them – each
would have a separate RCCP chart.
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Resource Chart Tab
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• Pick a constraint from drop down
• Chart is generated automatically
• There are 2 views available
• Past due projection: current past due
estimated recovery date plus, if no action
plan on capacity gap, system will
estimate future past due
• No past due projection: you will only see
current past due recovery. If future
capacity gap , burden will not show as
past due
• Refresh option will update EDI to the most
recent information, if missing cycle times you
need to go back and update.
• On Approved project, default view is LIVE
which will pull the most recent EDI snapshot
and you can always go back to CACHED view
which will pull the information as it was
originally submitted
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Demand Burden Chart – Escalation Ready
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• Escalation ready burden chart
• “End to end” view of supplier capacity –
each blue bar represents the burden on the
machine areas listed on the X-axis.
• It tells us the average overall weekly CAT
burden on a given resource looking forward
5 months (EDI).
• Burden bars are created from Demand at
the Demand tab x provided Actual cycle
times.
• The burden chart is a snapshot in time of
current burden.
• Demonstrated Capacity is normalized to
100% for all machine areas
Demand Burden Chart view is also
available for non escalation ready as
a second view.
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Stoplight Chart Tab
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• Provides a centralized location to view the status of all constrained resources.
• Cached/Live/Refresh features available
• Percentages represent percent burdened to Current capacity
• To pass quality gate action plan must be provided for resources above 100%
• Color coding convention:
• Green: Burden < Current
• Yellow: Burden > Current < Planned
• Red: Burden > Planned
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Planned Capacity Tab
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1. Planned Capacity for each
resource is defaulted to current
capacity
2. Pick constraint at the left
3. Edit any of the fields to reflect
supplier action plan to meet
demand
4. Save before moving to next tab
To cancel all you edits, you can move from
edit mode to demonstrated capacity and this
will copy all demo capacity again.
• Planned Capacity is the yellow line on the resource chart
• It reflects the proposed plan to increase current capacity when
there is a future capacity gap
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Action Plans Tab▪ Constrained resources with burden above 100% need an action plan
▪ Should be realistic and developed in collaboration
▪ Consider supplier lead times to flex their capacity for a given resource
▪ Burdened resources will automatically populate from stoplight chart and will have an alert symbol
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Align Parts – Enterprise Component Capacity Program (ECCP) Process
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2
• This step is not mandatory and can
be skipped
What you need to know:
• Enables category, component and
part number linkage.
• It is also a platform to automate
ECCP annual process from 6 months
to dynamic by generating SBOM and
Where- Made
• Manage category at a component
level which helps with strategic
capacity planning for 3-5 years
Steps:
1. Select part numbers to group
2. Select the Category
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Align parts – ECCP Process3. Select the component
4. Click on the align button
5. Repeat steps 1 through 4 for the
remaining parts
6. Click Next
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CAF Step
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2
3
4
1. Select Most Constrained Process
2. Add step
• Lead time to get to MAX
• What needs to increase?
• How many incremental hours will that
step provide (Max capacity - Current
capability)
3. Save
4. Submit for Approval
This is the last step so make sure to
validate all information before submitting
for approval
• CAF= Capacity Acceleration Funnel
• CAF steps are used to understand suppliers capability to ramp up towards EPP (upper bound) target
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ALERTS System will generate various types of alerts for a Project.
• Cancellation Alert: A project will get autocancelled after 90
days of being in progress.
− Alerts will be sent at 30 & 60 days to remind user to
complete project and submit for approval.
− Alert will be sent at 90 days to notify project has
been cancelled. All information in the system will be
deleted.
• Submission Alert: When supplier submits a project for
approval, RCCP owner will be notified
• Approve or Rejection Alert: When a project is approved or
Rejected supplier and RCCP owner will be notified.
• Expiration Alert: All projects will expire after 12 months.
− Alert will be sent at month 10 and 11 to remind user
to come back and refresh capacity information
− Alert Will be sent at month 12 to notify Project has
expired.
• Action plan Alert: One month prior to due date of an action
plan, supplier & RCCP owner will receive an email to
remind them that commitment is close to due date.
Note: Alerts will be sent via email and user can also track
down at Alerts page within project.
Example of Action plan Alert
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Step 5 - MaintenanceNeed for RCCP Coverage
• Make sure your project gets
approved
• Refresh data periodically to keep
your RCCP valid
Key Points
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Project Tracking – Option 1
• Go to Capacity Tool website https://demandvisibility.cat.com/DemandVisibilityTool/IRCCPSummary.do
• Under “RCCP” select “iRCCP Summary”, input supplier code.
• View button will take you to the approved project Read Only mode
Security Override
• External suppliers will only have access to projects linked to their supplier code/codes
• Caterpillar users will have access to see all approved projects (Read only).
• Cycle time information will be hidden and only available for people linked to that project
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Track Changes
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• For every refreshed project, capacity tool will provide a summary page of the high level information that was
updated with dates, user id and if change was performed by CAT or Supplier.
• You can find the changes summary at approval page, change log subpage.
Caterpillar: Confidential Green
Project Tracking – Option 2
• Go to Supplier Connect website https://supplierconnect.cat.com/wps/myportal/catconnect
• Under performance, select “Dashboard” , input supplier code, search for KPI “Capacity Management”
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Reading KPI “Capacity Management”
▪ Capacity management will be used as the RCCP acceptance criteria for SQEP certification
▪ KPI will show the coverage as▪ DET (Detailed)
▪ INT (Intermediate)
▪ N/A (No evidence of RCCP data)
▪ The KPI thresholds will be
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Reading KPI “Capacity Management”
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• Stoplight chart and Resource charts are displayed
• Hyperlinks to Capacity tool (DVT)
− "RCCP Type" Hyperlink will take you to approved Project
− Request RCCP will take you to "Request step"
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Summary
1. Rough Cut Capacity Planning (RCCP) helps proactively identify and address any future capacity gap within supply base to ensure an executable production plan at Caterpillar facilities.
2. RCCP projects are stored at Capacity tool on demand visibility website
3. Capacity tool enables supplier to input capacity information, provides a live demand view and helps set up , document and track action plans.
4. After an RCCP Project is approved, information will be stored and copied for refreshed projects.
5. Approved projects on Capacity tool, serve as Capacity Management evidence for SQEP certification.
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