MRP CAPACITY PLANNING CHECKLIST

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--- WORK CENTER DEFINITION & VALIDATION ---
[ ] Work Center Code
[ ] Work Center Description
[ ] Available Capacity (Units/Hour)
[ ] Setup Time (Minutes)
[ ] Work Center Type (Machining, Assembly, Inspection, Packaging)
[ ] Last Capacity Review Date
[ ] Special Instructions / Notes

--- RESOURCE AVAILABILITY ASSESSMENT ---
[ ] Current Labor Hours Available (Per Week)
[ ] Equipment Capacity Utilization (%)
[ ] Tooling Availability (Units)
[ ] Date of Last Capacity Review
[ ] Projected Labor Hours Available (Next Quarter)
[ ] Notes on Unexpected Downtime Events (Past 6 Months)
[ ] Overtime Hours Approved (Weekly)

--- BOTTLENECK IDENTIFICATION ---
[ ] Describe the suspected bottleneck process step.
[ ] Current cycle time (minutes)
[ ] Theoretical maximum cycle time (minutes)
[ ] Work-in-Progress (WIP) inventory level (units)
[ ] Possible causes of the bottleneck (select all that apply) (Equipment Failure, Lack of Skilled Labor, Poor Process Design, Material Shortages, Inefficient Scheduling)
[ ] Date of bottleneck observation
[ ] Time of bottleneck observation

--- PLANNED CAPACITY VS. DEMAND ALIGNMENT ---
[ ] Forecasted Demand (Units)
[ ] Available Capacity (Units)
[ ] Difference (Demand - Capacity)
[ ] Capacity Shortfall Scenario (No Shortfall, Minor Shortfall (0-10%), Moderate Shortfall (11-30%), Significant Shortfall (31-50%), Critical Shortfall (>50%))
[ ] Date of Forecast/Capacity Assessment
[ ] Notes on Alignment Issues / Assumptions
[ ] Potential Mitigation Strategies Considered (Overtime, Subcontracting, Prioritization, Expediting, New Equipment)

--- SCHEDULING RULES & PRIORITIZATION ---
[ ] Priority Level Minimum Stock
[ ] Prioritization Criteria (Select all that apply) (Due Date, Order Quantity, Customer Importance, Material Criticality, Production Sequence)
[ ] Scheduling Method (First Come, First Served (FCFS), Earliest Due Date, Critical Ratio, Shortest Processing Time)
[ ] Maximum Overtime Hours Per Week
[ ] Date Scheduling Rules Last Reviewed

--- ALTERNATIVE CAPACITY OPTIONS ---
[ ] Potential Overtime Hours Available (per week)
[ ] Outsourcing Feasibility (Highly Feasible, Moderately Feasible, Not Feasible)
[ ] Estimated Outsourcing Cost Increase (%)
[ ] Subcontracting Options Explored? (Yes, No)
[ ] Details on Subcontractor Quotes/Contracts
[ ] Date of Last Subcontractor Quote Review
[ ] Potential Additional Equipment Options? (Lease, Purchase, None)

--- PREVENTATIVE MAINTENANCE SCHEDULE ---
[ ] Next Scheduled PM Date
[ ] Maintenance Cycle Count (e.g., hours, days)
[ ] PM Procedure Description/Link
[ ] PM Task Completed (Yes/No/Partial) (Yes, No, Partial)
[ ] Date PM Completed
[ ] PM Notes/Observations
[ ] Attach PM Documentation (PDF, Image)
[ ] Estimated PM Duration

--- CAPACITY BUFFER AND CONTINGENCY PLANS ---
[ ] Overtime Authorization Limit (Hours/Week)
[ ] Approved Outsourcing Vendor List (Vendor A, Vendor B, Vendor C)
[ ] Next Review Date of Contingency Plans
[ ] Maximum Outsourcing Percentage (of Total Production)
[ ] Description of Emergency Production Relocation Plan (if applicable)
[ ] Primary Contact for Outsourcing Coordination (Contact 1, Contact 2, Contact 3)

--- DATA ACCURACY AND INTEGRATION ---
[ ] Bill of Materials (BOM) Accuracy Score (%)
[ ] Lead Time Accuracy Score (%)
[ ] Data Synchronization Method (Real-time, Batch, Scheduled)
[ ] Last Data Synchronization Date
[ ] Description of Data Validation Procedures
[ ] Integrated Systems (Select all that apply) (ERP, WMS, CRM, Shop Floor Control)

--- DOCUMENTATION AND COMMUNICATION ---
[ ] Summary of Capacity Planning Assumptions
[ ] Stakeholders Informed of Capacity Plan (Production Manager, Sales Manager, Supply Chain Manager, Engineering Manager)
[ ] Date of Last Communication Review
[ ] Communication Log (Emails, Meeting Minutes)
[ ] Next Communication Review Date
[ ] Reviewer Signature

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