The plan exceeds capacity every week
When every week shows an overload, the inputs are usually wrong before the plan is.
What you hear: “Every week in the capacity check is over 100 percent, but the plants still ship most of the orders.”
Check first: Pull eight weeks of actual output for the most overloaded line and compare it to the rate in the check.
Likely causes
- The line rates in the check are lower than what the lines really run.
If every week is over and the plants still ship, the check is wrong, not the plants. The usual cause is a rate or calendar that does not match what the line actually does. At the company, a stale rate on Line 3 once made every week look overloaded. Fix the input first, then read the load again.