The Production Capacity Plan is intended to confirm that the production capacity to support Kasai UK requirements will be available and not constrained by the mix of product required.
Minimum Content Requirements
The Supplier must systematically define and document:
The process bottlenecks and their location within the overall production process
The variant mix constraints
A Production Capacity Plan shall be completed for each process step indicated on the Process Flow Chart.
Document Description
Item
Completion Instructions
Project
Kasai UK Vehicle project for which the product is being developed / manufactured.
Kasai UK Important Part
Tick all boxes that apply to the product being developed / manufactured.
Document Reference No./ Version
The Suppliers reference no. and version no. for the document.
Document Revision Date
The date of the latest revision of the document.
Document Origin Date
The date when the document was first issued.
Supplier Name
Supplier Company name.
Supplier Plant
Location at which the product will be produced.
Supplier Code
Unique code to each supplier, issued by Kasai UK Purchasing Dept.
E-mail
The E-mail address of the person who created / revised the document.
Author
The name of the person who created / revised the document.
Tel
The telephone number of the person who created / revised the document.
Part Name
The part name or description as identified on the product drawing.
Part No. & Issue Level:
As issued by Kasai UK design department.
Design Note No. / DEVO
The latest design note number that applies to the product being developed / manufactured.
Sequence No. & Symbol
Process stage indicator taken from the Process Flow Chart.
Process Name
Name of process stage taken from the Process Flow Chart.
Type of Machine / Equipment
Facility used at this stage of the process, taken from the Process Flow Chart.
Planned Capacity
Hourly/shiftly/weekly -output (as appropriate)
Overtime capacity per hour/shift/week available
Working hours per week
Total hours worked per week i.e. excluding non-productive time, e.g. official breaks, meetings etc.
(This should include hours on all shifts in the week)
Shift pattern
Shift pattern to be used by the product manufacturing facility, i.e. 2-shift (days & nights or double days), 3-shift, etc.
Working weeks per year
Number of working weeks per year for the product manufacturing facility.
Total hours available per year
Calculation based on multiplying the working hours per week by the working weeks per year
Number of personnel
Number of staff required to operate the product manufacturing facility.
Scrap rates
Percentage of expected non conforming material to be generated during the manufacturing process
Variant mix constraints
Are there any constraints in the manufacturing process caused by the variant mix/ product diversity?
If yes, input ‘Yes’ on the form and attach a detailed explanation.
If no, input ‘No’.
Changeover times
The time for any required tooling changeover for manufacture of different products in the facility, quoted as a time per changeover.
Changeover frequency
The frequency of any required tooling changes
% facility availability
These percentages are for the facility available time for each of the categories
Tool life expectancy
Life of the tooling until refurbishment or replacement will become necessary
Efficiency levels
Overall efficiency level expected from the product manufacturing facility during its total working time.
Completed By
Supplier person responsible for capacity planning
Signed
Signature of above
Date
Date completed
Review Frequency
Detail the frequency that capacity is reviewed.
Next Review Date
Date of next formal capacity review.
For rules related to document submission, refer to the Submission Rules page.
