Process Capacity Sheet Math

The process capacity sheet, also known as a table of production capacity by process or production capacity chart or process capacity table, is one of the three basic tools for establishing a standard operation. The other tools are the standard work combination sheet and standard work sheet. All three standard operations sheets are populated with data obtained through direct observation (as is the time observation form).

The process capacity sheet, as the name implies, is for the purpose of determining a given process’ capacity for a shift, and thus its ability to meet takt time. This determination is made through the calculation of each process step’s capacity, considering the available time per shift, completion time, and tool change time, and other factors, as required, for each single work piece. The process’ overall capacity is defined by the bottleneck step, which may be addressed through things like changeover time reduction and machine and/or operator cycle time reduction. Some versions of the sheet, like the one below, also provide fields for the number of required operators to satisfy takt time and calculated maximum output.

The figure below shows a populated process capacity sheet, along with alpha “call-outs” by which the math is explained.

 process capacity sheetprocess capacity 1process capacity 2process capacity 3process capacity 4Other related posts: Available Time, Machine Cycle Time