Improvement of Long-Term Capacity Planning
Explore how we improved a client’s long-term capacity planning with a model tailored to the unique needs of the client.
GOOD STORIES
When a client transitioned to 24/7 production, existing planning methods quickly fell short. With no buffer time and increased complexity, the need for a clearer, more detailed planning approach became critical. Our team delivered a lightweight, Excel-based tool that brought structure, visibility, and alignment across planning and production.
THE CHALLENGE
The client lacked a clear overview of the individual steps in their production processes, particularly in terms of staffing and resource allocation. Previously, production operated on a two-shift model (morning/evening), with night and weekend hours serving as a buffer. However, a strategic shift to 24/7 production eliminated this buffer, placing significantly higher demands on planning and coordination.
With complex processes involving numerous interdependencies, it became increasingly difficult for the client to maintain visibility over all activities – especially when sudden changes occurred. This made it critical to identify in advance what needed to be prepared in order to maintain flow and avoid costly delays.
OUR APPROACH
To address the client’s need for better process visibility and coordination, we developed a lightweight planning tool that requires minimal implementation effort. Built in Excel, the tool allows detailed planning of production activities, including what needs to be done, when, and with what staffing levels.
The solution consists of three interconnected components – Processes, Planning, and Overview – that work together to give both detailed control and visual insight.
This approach gave the client a hands-on, transparent way to manage the shift to 24/7 production without the complexity, cost, or time of implementation of large-scale commercial software.
Users define standard workflows, detailing each step’s duration, dependencies, and staffing requirements.
Users map out when each process occurs, updating the timeline in real-time as delays or changes occur. The interdependencies defined in the processes ensure a dynamic plan which updates automatically as changes are made.
Automatically generated visualizations show all planned activities within a selected time frame, aligned with the relevant equipment. Color-coded highlights indicate delays or accelerations, and staffing levels are visualized to identify potential peaks in workload.
THE RESULTS
Implementing the tool in the organization led to greater alignment between planning and production by providing a clearer overview of both current workflows and upcoming demands, including peak production periods. This enhanced visibility enabled more proactive decision-making and reduced the risk of bottlenecks.
To further improve the collaboration between planning and production, a refined structure for how to work with planning was implemented. This ensured right-time communication between the teams, leading to more accurate planning and pro-active use of the plan on the shop floor, leaving both planning and production teams more satisfied with each other’s work.
Effective planning is essential for maximizing efficiency and making the most of available production time. It highlights bottlenecks before they become problems and ensures the right resources are in place when needed.
Clear, visual plans replace informal, mental ones, making operations easier to understand and improving team coordination. Planning also enables accurate forecasting, allowing teams to track progress and set realistic expectations.
Most importantly, it creates alignment across roles, reduces uncertainty, and supports timely preparation – leading to smoother, more confident, and less stressful production.
GET IN TOUCH
Want to see how we can help your organization gain control, visibility, and alignment in complex production environments?
Get in touch with Kristian Lindholm from our Improvement team. Kristian specializes in practical, data-driven planning solutions for manufacturing. He’ll walk you through how a simple tool can make a big difference in supporting 24/7 operations and reducing stress on the floor.
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