rough cut capacity planning

Caterpillar: Confidential Green

Fundamentals & Corporate Tool

1

Rough Cut Capacity Planning


Agenda▪ Capacity Planning Overview

▪ Intermediate Process

▪ Capacity Planning Tool

▪ Maintenance & Project Tracking

▪ Summary

2

✓ Request

✓ Initiate

✓ Capacity

✓ Demand

✓ Cycle Time

✓ Planned Capacity

✓ Resource Chart

✓ Stoplight chart

✓ Action Plans

✓ Align Parts

✓ CAF Steps

✓ Alerts


Capacity planning overview

3


What is RCCP?

4


Benefits of tools for Suppliers & Caterpillar

Supplier

• Improved performance

• Lowered operations cost

• Balancing load

Caterpillar

• Executable build plan

• Supports enterprise S&OP


Intermediate RCCP Process

6


Key Definitions• Burden

• The amount of required capacity in order to meet demand

• Capacity

• The capability of a worker, machine, work center, plant, or organization to produce output per time period, independent of burden

• Routings

• Which parts go through which resources? This is an essential piece of information for completing RCCP (forward looking) charts, as it helps determine the quantity of parts going across a resource

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Outcomes

8

RCCP Chart (Resource Chart)

• Forward looking, 18 months

• For processes that appear constrained based on burden chart

• May be required for all processes, if other groups using the RCCP (e.g., certain sourcing councils) require it

• Requires part routings to complete

Burden Chart

•End-to-end current state view of burden vs. capacity for processes across which Caterpillar parts run

•Which areas appear constrained (>80% burdened)?


Intermediate RCCP Process Overview

Supplier

Information

Capacity Data

Collection

Initiate RCCP

Project in DVT

Pre-workSupplier

Input

Analysis &

Report OutMaintenance

0

20

40

60

80

100

120

140

Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14

H

o

u

r

s

Month

RCCP Chart (Hours)

CAT Demand CAT Past Dues Demonstrated Capacity for CAT Maximum Capacity for CAT Planned Capacity for CAT

Burden ChartMaintain iRCCP

Resource Charts for

Constrained, or All

Resources

Supplier

Onboarding

RCCP Request

Caterpillar/Supplier

Request to

Open/Refresh RCCP

Project in DVT


Capacity Planning tool

10


REQUEST

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Step 1- RCCP Request

https://demandvisibility.cat.com/DemandVisibilityTool/index.do

1. Go To Chrome Browser (preferably)

- Enter the following Link:

2. Input CWS id and password > Agree to terms 3. For access please contact:

[email protected]

Need for RCCP Coverage

• 2 Types of Request :Open New project

or Refresh a previous one.

• Any External supplier or Caterpillar

person with access to Caterpillar

Capacity Tool (DVT) can request an

RCCP project.

• Requestor should assign at least one

Caterpillar contact and could also assign

a supplier contact if desired.

• A notification email will be sent to

selected contacts and previous RCCP

owner.

Key Points

https://demandvisibility.cat.com/DemandVisibilityTool/index.do

mailto:[email protected]


• Go to RCCP > RCCP PROJECT


1. Input supplier code linked to the

project (up to 3)

2. Create new intermediate per

selection

3. Select RCCP Area:

DEFAULT: One single RCCP

area

OTHER: Use to differentiate

an additional RCCP area

4. If you select OTHER, provide a 3

digit name for this area

5. Create project

1

2

3

5

5Supplier area is a user defined field that identifies

separate work areas under the same supplier code

4

Request RCCP- New Project


1. Input supplier code linked to the project (up

to 3)

2. You get a view of previous project, when it

was last updated and by whom

Now you have 2 options:

1. Create New: All the information from

predecessor Project Will be copied (Supplier

codes, RCCP area configuration)

2. Create New Intermediate Per Selection: This

allows you to change original configuration,

add or remove supplier codes or rename

RCCP area.

- Select RCCP Area:

DEFAULT: One single RCCP area

OTHER: Use to differentiate an additional

RCCP area

-If you select OTHER, provide a 3

digit name for this area

- Create project

Request RCCP Project Refresh


Request Tab

After Save as Request

Email will be sent to all

contacts within the

project

Supplier contact

is optional

If you are the RCCP owner you

may skip request and Initiate

Caterpillar contact can choose to

cancel the request

Must provide a

Caterpillar contact that

will be the RCCP

owner (Initiator).

For refreshed

projects, system

will bring previous

RCCP owner

Caterpillar: Confidential Green 17

Communication Examples

Cancel Notification

Request Notification


INITIATE

18


Step 2- Pre-workExplain supplier the need and level of detail we require for RCCP

•Supplier buy in and support before asking

for data

•Communicate value to both Supplier and

Caterpillar in doing RCCP

•Supplier will receive a notification that

RCCP project has initiated and the link to

Capacity site

•Keep all interested parties (supplier,

manager, buyer) informed

Key Points


1. Date supplier was contacted

2. Select Cycle Time Type

• Actual (specific to each part) – this

will give the most accurate analysis

• Average – meets requirements for

coverage, but least accurate

• Weighted average – i.e., an average

where part mix is incorporated

3. Select Part Routing Type:

• Constraint Process only

• All process routing

4. Use Build Index?

• YES - 6 Months of EDI and the

remaining 12 are extrapolated from

Demand INDEX

• NO – Provides 18 months of

available EDI signal

5. Search Supplier contact

6. Select auto initiate period from dropdown

12

3

4

5

Initiate screen can ONLY be input by a Caterpillar

person which will be the RCCP owner of the project

Initiate Tab

6


Communication Examples

21

Project Initiated Notification


RCCP Level of Information

22

Escalation Ready

• For burden calculation use

demand from demand tab x

cycle times for each part

• All part routings & cycle times

must be provided

• Actual cycle are required


Step 3 – Supplier InputData Collection

• There are 2 input data options: Manual

and Upload from Template

• For a refreshed project, download

template will bring previous project data

• For a successful upload make sure you

follow format recommendations on the

upload screen

• All fields need to be filled for Save option

to be enabled

• On each tab make sure you Save your

data before moving to a different tab,

otherwise your information will be lost

Key Points


CAPACITY

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Capacity Tab1. Resource: All areas / Machines in facility that are used for the

production of Caterpillar parts.- Character Restricted

2. Resource Description: Complete resource name.

3. Process represented by area

4. Constrained By: choose whether the process is constrained by

labor or machine

5. Demand Unit of Measure: This Can be Pc parts/Tons or Hours

6. Run Rate Type: Actual/Planned

7. Run Rate: Indicate the average capacity rate (planned or actual)

per hour per resource. This can be pieces per hour, or tons per

hour

8. Total Average Weekly Demand on all Resources: Make sure it

aligns to selected unit of measure (5)

9. CAT Average Weekly Demand: (Caterpillar Tier 1 only)

10. CAT Load %: % of CAT load on that area (time consumed not qty)

11. Past Dues: Indicate the amount of current past dues for each

work area. Note that these are internal past dues

12. Caterpillar Past Dues: indicate the amount of internal past dues

per resource that are Caterpillar parts

1

2

3 4

5

6 7

8 9 10

11 12


Capacity Tab

13. Cur # of Resources: Specify the number of resources that are

currently being used in production

14. Max Resources: Specify the maximum amount of resources that

could be used in production

15. Cur Hours per Shift: Indicate the production hours per shift. Do not

include any break time

16. Max Hours per Shift: Include the maximum amount of production

time possible

17. Cur # of Shifts Assigned

18. Max # of Shifts

19. Cur # of Days per Month: Indicate the current number of days per

month that each resource is in production

20. Max Days Work: Identify the maximum amount of days per month

that supplier can work for each resource/machine area

21. OEE %: Indicate the overall equipment effectiveness(OEE) in %.

EX 100%

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13 14

15 16

17 18

20

21

Auto populated field

Cycle Times UoM. Depending of user selection at Demand UoM

the system Will define the cycle time UoM that is required at Cycle

times page.


1-3 – Resource, Description and Process

Resource Description• Longer resource name

Process

• For every machine area in supplier’s facility,

identify the process corresponding to the area

Resource

• Identify resource that produces ANY Cat parts (does

not have to be dedicated)

• Machines with similar part routings and cycle times

can be listed as a single line item with the number of

machines noted in the Number of resources field (13)

Examples:

• Work center consists of 3 different machines that

perform different operations, handle different parts,

or have very different cycle times: Each machine

needs to be listed separately

• If a weld station has 2 identical weld machines, list

“weld” as one machine area and adjust the number of

resources

Resource field is format restricted, 3 to 20 characters

no spaces or special characters allowed.

1

2

3


4 – Constrained by Labor or Machine

Select the constraint type: Labor or Machine

• Could the resource produce more parts

with double the labor? Ex: Welding

operation (labor constraint) vs. Machining

center (resource constraint)

• This determines if labor or machines should

be used to determine number of resources

4


5 – Demand Unit of Measure

• Use the drop-down box to indicate if demand is

given in pieces, tons or burden hours

• Depending of user input at Demand UoM the

system will define the unit of measure cycle

times need to be entered in at Cycle times page.

5


6 & 7 – Run Rate Type & Run Rate

Run Rate Type

Actual Capacity Rate (demonstrated historically)

• Find the actual number of pieces produced per hour at each machine

• The purpose is to find the average hourly exit rate at each machine

Planned Capacity Rate:

• Planned average number of pieces produced per hour across a single

resource in a machine area

Run Rate

Indicate the average capacity rate (planned or actual) per hour per resource. This

can be pieces per hour, or tons per hour

When Demand UoM is Hours consider the following:

• On manual input Actual and planned capacity rate will turn gray and default to “1” if

total average weekly demand is entered in burden hours as capacity rate is

already included in burden hour calculation.

• On Uploading from template, all fields must be filled for successful upload. For

Run Rate Type, planned or actual need to be typed in and Run Rate needs to be “1”

Only needed if demand is given in Piece Parts/Tons

6

7


8 & 9 – Total Average Weekly Demand on all ResourcesAverage CAT Weekly Demand

Average weekly demand should be forward looking, roughly a month or two :

This is the amount of burden shown in the Burden Chart (non escalation ready)

• Supplier must verify demand data based on their production

schedules

Total Average Weekly Demand : Specify total average weekly demand for

both Cat and non-Cat parts across all resources for that machine/resource

area

CAT Average Weekly Demand : One aggregate total average weekly demand

number for CAT Tier-1 demand across all resources in a machine area

8

9


10 – CAT Load %

Indicate the percentage of load that Caterpillar parts take up on that

machine/resource area.

• If the machine/resource is dedicated to Cat, the CAT Load is

100%.

• If the machine/resource is shared, what % of scheduled

production TIME is spent making Cat parts. This may be different

than the percentage of parts that are Caterpillar.

• Some suppliers will have a contractual obligation or limit set of

the percent of capacity dedicated to Cat. If this is the case, type

in that percentage.

10


Past Dues should be noted in the same units as your Total Average Weekly Demand/Total

Average Weekly CAT Demand

• Past dues are internal past dues, from machine to next process. These are not

past dues in terms of shipping to a Cat or Tier 2 facility.

Total Past Dues: For each resource, find out how many pieces/hours (CAT & Non-CAT) are

past due as of today

• Used to calculate the additional percent of burden that will be added by past

dues

Caterpillar Past Dues: For each resource, find out how many of the total pieces/hours past

due today are Caterpillar parts

• It is helpful, however, to know the number of CAT past dues to develop action

plans to alleviate any issues.

11 & 12 – Total Past Dues & Caterpillar Past Dues

• Past dues are a current snap shot in time regardless of the

duration over which they were accumulated

• Past dues burden the operation they are incurred on, not the

next operation they flow to..

11

12


Parts produced should be largely interchangeable

across all resources if listed on the same line item

13 & 14 – Cur Number of Resources & Max ResourcesCur Number of Resources

• For a given process, identify number of separate resources(man or machines)

that are currently being used to perform the same operations

• Resources can be combined if part routings and cycle times are similar for the

resources in question

Max Resources

For a given process, identify maximum number of separate resources (man

or machines) available to be used to perform the same operations

Example:

There is currently 2 laser cutter allocated to this area, however the supplier

has the ability to use use the 4 laser cutters installed if necessary

13 14


15 – 20: Operating ScheduleCur

Ener the total number of shifts per day, hours per shift that each

machine is currently scheduled to run (production time), and the

number of working days per month.

Max

Input the total number of shifts per day, hours per shift that each

resource could get scheduled to run (production time) and the

number of days per month at Max capacity.

12 Month Working Days:

Instead of average, you can now enter actual working days at each

month, removing any holidays or planned shut downs. This will

provide a more accurate Capacity view. When entering data in hours per shift

columns, only enter scheduled production

time which would not include

breaks/lunches


15 – 20: Operating ScheduleThe information for the operating schedule all gets

multiplied together to determine the total hours for the

burden chart

• This means that the hours per day is (Number of

Resources)*(OEE or Operating Efficiency)*(Hours per

Shift)*(Shifts Per Day)*Number of days

Having Hrs. per Shift x Number of Shifts (Cur/Max) > 24

represents over 24 hours per day.

On Manual Input fields will highlight red and on

Uploading form template file will throw an upload error.Upload Error

Manual Input


When filling out the Capacity Tab in Piece Parts…

If actual exit rates are available (historic demonstrated), then use

actual rates and not planned exit rates and ensure OEE defaults to

100%. In this case, it is 100% because time required to produce actual

output will capture process inefficiencies.

21 – OEE: Overall Equipment Effectiveness• OEE is used to find out overall effectiveness of each machine to

produce parts by factoring out losses

• Inefficiencies are tied to a machine area that result in a combination

of loss of availability, productivity, and/or first time yield for that area

• The calculation for the input to this field will vary depending on the

availability of historical performance metrics

The following slides will

break from the process to

provide more detail on OEE


What is OEE?

• OEE stands for Overall Equipment Effectiveness

• OEE is a measurement that defines

• Percentage time a machine was actually producing quality parts compared to the time it was planned to be producing quality parts

• Equipment’s actual productivity compared to the ideal productivity, during a specified period of time

• The difference between actual performance and ideal performance is identified as waste, which must be eliminated. “What gets measured, gets done!”

• The main difference between OEE and Operating Efficiency is while OEE measures waste with allocated buckets, which allows for identification and systematic elimination of waste “Operating Efficiency” is just an approximation of overall waste.

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OEE = Availability x Performance x Quality

• Planned Production Time: Total time the equipment is scheduled for production. It is the Total Available Time minus Unscheduled Time.

• Actual Running Time: Total time the equipment actually ran during the production time. Actual Running Time removes any downtime losses including, but not limited to:• Breakdown or Equipment Fault• Setup/Adjustment• Operations team member missing (absent, personal time, lunch, meeting, training, 5S activities, etc..)• Material Missing (parts, tools, fixtures, gauges, etc..)• Startup Loss (time spent for startup to reach the right operating conditions, for example heating a furnace)• Quality/Inspection• Tool Change (piece of equipment stopped for a tool change)

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Availability = Actual Running Time / Planned production Time



▪ Planned Method Time: Is calculated by multiplying the normal cycle time or theoretical time to produce one part times the total of all produced parts including defects

▪ Actual Running Time: Total time the equipment actually ran during the production time

▪ Performance should never be greater than 100%. If it is, that usually indicates that normal Cycle Time is set incorrectly (it istoo high).

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Performance = Planned Method Time / Actual Running Time

Note: If the Actual Running Time is continually over or under the Normal Cycle Time, the issue

needs to be investigated. If the Normal Cycle Time is believed to be incorrect, then the issue

needs to be fed back to the planning department for review.



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• Bad Output: The amount of scrap and/or rework produced during the set-up and Actual

Running Time. As with good output, it is measured in pieces, feet, inches, pounds, etc..

• Actual Output: The total amount of output, good and bad produced during the set-up and

Actual Running Time, also measured in the same units, pieces, feet, inches, pounds, etc..

• Good Output: The amount of good, sellable output that was produced during the set-up and

Actual Running Time, where output could be pieces, feet, inches, pounds, or other depending

on the operation.

Calculated : Actual Output – Bad Output

Quality = Good output / Actual Output


Capacity Tab - Manual Input

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For refreshed

projects update

demand and

operating schedule

per resource

Save or Delete

resource as needed

For each resource

fill all data boxes? Check out

available tooltips

Hit +New to add a

resource


Capacity Tab - Upload From Template

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1. Download template

(RCCP_Capacity)

2. Fill in information following format

rules & Save

3. Choose file to upload

• To delete a resource you need to go to

detail tab, you can not remove from

template.

• To rename a resource do it from detail

screen to avoid same resource

recorded twice.

2

1

3


Key Format Rules

44

• Only Notes column can be left blank

• Resource Name: Name should be from 3 to 20 characters, no

spaces, no special characters

• Unit of measure allowed values: "Hours", "Pieces", "Tons"

• For unit of measure = “Hours” :

Run Rate Type = “Planned or Actual”

Run Rate = “1” (0 is not allowed)

• Number of shifts x Hours per shift can not be higher that 24

hours

• % OEE and Cat load expressed in format of 0 to 1

• If no Past dues value must be “0”

• On escalation ready : Average weekly demand still needs a

value, input can be 0Upload Success

Upload Error


Demonstrated Capacity is normalized to 100% for all

machine areas.

Trigger for Capacity Planning: Any machine area at or

above 80% Capacity should be selected as a constraint

for Capacity Planning. If no machine areas are at 80%,

select the most burdened area.

At times, capacity planning may be required for all areas.

This is done at the discretion of other groups that may

use the results of this iRCCP. Minimum standards for

“coverage” are for all processes more than 80%

burdened, or the most constrained process.

WHY? We want to

extrapolate demand on the

constrained resource out

18 months and compare

Caterpillar demand against

the constrained area’s

capacity to ensure an

executable build schedule.

• Burden bars are created from the Total Average Weekly Demand on all

Resources provided at Capacity Tab. It tells us the average overall burden,

CAT & Non-CAT, on a given resource looking forward 4-6 weeks. The burden

chart is a snapshot in time of current burden on the machine areas listed on

the X-axis.

Reading The Burden Chart – Non Escalation Ready


PARTS

46


Parts Tab contains a list of all parts with demand for the

supplier code selection.

There are 3 main functionalities for this page:

1. Supplier Local part storage: Supplier can enter their

own local part number and save that relationship with

Caterpillar part, this for future reference at Cycle times.

2. Part Exclusion : User can select a list of parts that do

not need to be considered within project's scope.

Parts Excluded Will not be displayed at Demand tab.

3. Review the number of resources each part is tied to at

cycle times.

If user does not need to exclude or save local parts, they

can skip this step and go Next.

Parts Tab

If a part is missing cycle time, "Resources

with part" Will display blank

1 2 3


Parts Tab - Manual Input

A part can not be excluded if it is linked to

at least one resource.

1 2

Option 1

1. To exclude a Part:

• Check the Exclude box of the

respective part

• Provide a reason to Exclude by

selecting from drop down.

2. Part Numbers (From Supplier)

• Type the local part number related to

the respective Cat Part


Parts Tab - Upload From TemplateOption 2

• Hit Download parts button

• Fill template according with format rules

1. Exclude: true = part excluded ; false = part not

excluded

2. Reason To Exclude : NPI , Pass-through Part

3. Part Numbers (From Supplier) : Enter supplier

local part for each Caterpillar part.

Note: Resources with part column is not an editable

field.

• Save All_Parts file to your local drive

• Hit Upload parts

• Choose file and Upload

1 2 3

A part can not be excluded if it

is linked to at least one

resource.


DEMAND

50


Demand Tab• System generated (Capacity tool pulls

information on a daily basis from MRC, SCDW

and CLIDB)

• Depending on selection at initiate screen system

will bring EDI & DEM INDEX or just EDI for 18

month scope.

• Supplier can add Manual demand (Tier 2).

• Upload/download feature for manual demand

available.

• Refresh Button will pull most recent EDI.

• Parts Excluded at parts page will not be

displayed at demand tab

Demand Index Selected on Initiate Screen

18 Months of EDI


CASH / LIVE / REFRESH

52

When a project is in progress

Cached • Capacity tool will take a snapshot of EDI /DEMAND INDEX of that moment in time when user got into demand tab.

• If the Project is not completed within the next few days and user wants to have an updated view just hit Refresh

System will ask confirmation before it refreshes data.

• Once it has been refreshed you can not go back to original data. New information has been Cached

• RCCP CHART/ DEMAND/ STOPLIGHT CHART show this refresh option.

• Live will be disabled at this point.

Refresh

Cached • Anyone with access to the approved project has 2 view options Cached and Live. They can switch back and forth

on this view.

• Live is the default view when opening an approved Project.

• Cached will show demand as it was originally submitted and Live is the EDI/ INDEX update for the day.

• RCCP CHART/ DEMAND/ STOPLIGHT CHART has these view options.

• Refresh button is disabled at this point.

When project has been Approved:


Manual Demand - Manual Input

53

• Purpose is to capture Tier 2 parts on capacity analysis

• On demand refresh if manual part# & facility combination is not

included on new EDI, tool will keep manual demand numbers

Option 1

• Hit add demand icon

• New row will show- Forecast Type Manual

• Select receiving facility from drop down

• Type PN & month over month forecast


Option 2

• Hit Download manual demand for uploading button


• Save Demand_Upload file to your local drive

• Hit Upload Manual Demand


Manual Demand – Upload From Template


Filters

Each column within the Demand

tab can be filtered per user needs

Demand – Additional FeaturesDownload demand

• 18 Months of demand can

be downloaded to excel

• Option available for

Cashed and Live views


CYCLE TIMES

56


Cycle Times Tab - Manual Input1. Pick a constraint from the left

2. Review auto defined Unit of measure and make

sure values entered are aligned

3. Identify ALL Caterpillar Tier 1 part numbers that

are routed across the identified constraint and

type each at part number rows

4. Identify actual/average cycle times (or Tons) for

each part number that pass through the

constraint

5. Repeat for all constrained areas identified in

burden chart – or ALL areas if Escalation ready

• For Cycle time, blanks and zero values are not allowed.

• On Escalation Ready user must provide part routings and cycle times for ALL parts and ALL

processes, Next button will not enable until all parts are included in at least one resource.

• On Non Escalation Ready user must provide part routings and cycle times for all constrained

process

• Local part number will be automatically pulled from Parts page.

• If a part needs to be excluded from analysis this Will have to be documented at parts page

with a reason for exclusion. Cycle times can not be entered for excluded parts

1

2

3 4


Cycle Times Tab - Upload From Template

• All resources can be captured in a

single file

• For Cycle time blanks and zero

values are not allowed.

• Parts excluded can not have cycle

times

• Hit Upload Cycle Times button

• Hit Download Cycle Times button


• Save RCCP_Cycle_Time file to your local drive

• Hit Choose File



Key Format Rules

59

• All fields must have a value, no blanks allowed

• Resource Name should exist in the capacity tab

• Unit of Measure allowed values:

“CycleTimeMins” , "Pieces" or “Tons” No spaces

Consider this value is already defined by system,. Using a

different unit of measure than the auto defined one Will

generate an upload error.

• Part Number same part can only exist once per resource

• Cycle time needs to be greater than 0

• Parts excluded can not have cycle times Upload Success

Upload Error


RESOURCE CHART

60


Step 4 – Analysis & Report OutResource Chart and Action Plans

• For each constrained process, resource

chart will show 18 months outlook of

capacity vs demand

• For any capacity gap, action plan needs

to be captured

• Planned capacity is used to reflect action

plan and validate if proposed plan will

meet demand

• Burden Chart on resource tab is based

of EDI x Cycle times (Hrs.)

Key Points


Resource Chart Components

CAPACITY BURDEN

Operating

Schedule

Supplier Provided

Data

Number of

Resources

Demand Index

EDI

System Generated

Data

Part Numbers

Cycle Times

(avg or actual) &

Routings

OEE or Efficiency

Factor

CAT Load%

Manual Demand


Interpreting the Resource Chart

63

There are three different capacity definitions for a machine area/resource

shown in an RCCP chart: Demonstrated, Planned, and Maximum. Each

definition of capacity is visually represented by a line in the RCCP chart.

Demonstrated Capacity is created by combination of:

•OEE, Hrs. per shift, # shifts assigned, # of Days per month, # of resources, %

Cat Load

Max Capacity is created by combination of:

•OEE, Max Hrs. per shift, Max # shifts assigned, Max Days Work for the month,

Max # of resources, % Cat Load

Planned Capacity deviates from Demonstrated if the RCCP Chart shows that

burden is greater than demonstrated capacity. Action plans should be

developed & reflected in the planned line.

Burden Bars are built from the cycle times/part routings & Demand (Demand

Tab). Each color represent the portion of burden per Cat receiving location

CAT% Load is also factored into the capacity definitions of that machine

area/resource. The lines in the RCCP charts are discounted to reflect

actual % of total capacity allocated to Caterpillar.

Each machine area/resource listed in the Capacity

Tab can be modeled with Capacity Planning if we

have routings and cycle times for them – each

would have a separate RCCP chart.


Resource Chart Tab

64

• Pick a constraint from drop down

• Chart is generated automatically

• There are 2 views available

• Past due projection: current past due

estimated recovery date plus, if no action

plan on capacity gap, system will

estimate future past due

• No past due projection: you will only see

current past due recovery. If future

capacity gap , burden will not show as

past due

• Refresh option will update EDI to the most

recent information, if missing cycle times you

need to go back and update.

• On Approved project, default view is LIVE

which will pull the most recent EDI snapshot

and you can always go back to CACHED view

which will pull the information as it was

originally submitted


Demand Burden Chart – Escalation Ready

65

• Escalation ready burden chart

• “End to end” view of supplier capacity –

each blue bar represents the burden on the

machine areas listed on the X-axis.

• It tells us the average overall weekly CAT

burden on a given resource looking forward

5 months (EDI).

• Burden bars are created from Demand at

the Demand tab x provided Actual cycle

times.

• The burden chart is a snapshot in time of

current burden.

• Demonstrated Capacity is normalized to

100% for all machine areas

Demand Burden Chart view is also

available for non escalation ready as

a second view.


STOPLIGHT CHART

66


Stoplight Chart Tab

67

• Provides a centralized location to view the status of all constrained resources.

• Cached/Live/Refresh features available

• Percentages represent percent burdened to Current capacity

• To pass quality gate action plan must be provided for resources above 100%

• Color coding convention:

• Green: Burden < Current

• Yellow: Burden > Current < Planned

• Red: Burden > Planned


PLANNED CAPACITY

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Planned Capacity Tab

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1. Planned Capacity for each

resource is defaulted to current

capacity

2. Pick constraint at the left

3. Edit any of the fields to reflect

supplier action plan to meet

demand

4. Save before moving to next tab

To cancel all you edits, you can move from

edit mode to demonstrated capacity and this

will copy all demo capacity again.

• Planned Capacity is the yellow line on the resource chart

• It reflects the proposed plan to increase current capacity when

there is a future capacity gap


ACTION PLAN

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Action Plans Tab▪ Constrained resources with burden above 100% need an action plan

▪ Should be realistic and developed in collaboration

▪ Consider supplier lead times to flex their capacity for a given resource

▪ Burdened resources will automatically populate from stoplight chart and will have an alert symbol

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ALIGN PARTS

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Align Parts – Enterprise Component Capacity Program (ECCP) Process

1

2

• This step is not mandatory and can

be skipped

What you need to know:

• Enables category, component and

part number linkage.

• It is also a platform to automate

ECCP annual process from 6 months

to dynamic by generating SBOM and

Where- Made

• Manage category at a component

level which helps with strategic

capacity planning for 3-5 years

Steps:

1. Select part numbers to group

2. Select the Category


Align parts – ECCP Process3. Select the component

4. Click on the align button

5. Repeat steps 1 through 4 for the

remaining parts

6. Click Next


CAF STEP

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CAF Step

1

2

3

4

1. Select Most Constrained Process

2. Add step

• Lead time to get to MAX

• What needs to increase?

• How many incremental hours will that

step provide (Max capacity - Current

capability)

3. Save

4. Submit for Approval

This is the last step so make sure to

validate all information before submitting

for approval

• CAF= Capacity Acceleration Funnel

• CAF steps are used to understand suppliers capability to ramp up towards EPP (upper bound) target


ALERTS

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ALERTS System will generate various types of alerts for a Project.

• Cancellation Alert: A project will get autocancelled after 90

days of being in progress.

− Alerts will be sent at 30 & 60 days to remind user to

complete project and submit for approval.

− Alert will be sent at 90 days to notify project has

been cancelled. All information in the system will be

deleted.

• Submission Alert: When supplier submits a project for

approval, RCCP owner will be notified

• Approve or Rejection Alert: When a project is approved or

Rejected supplier and RCCP owner will be notified.

• Expiration Alert: All projects will expire after 12 months.

− Alert will be sent at month 10 and 11 to remind user

to come back and refresh capacity information

− Alert Will be sent at month 12 to notify Project has

expired.

• Action plan Alert: One month prior to due date of an action

plan, supplier & RCCP owner will receive an email to

remind them that commitment is close to due date.

Note: Alerts will be sent via email and user can also track

down at Alerts page within project.

Example of Action plan Alert


Step 5 - MaintenanceNeed for RCCP Coverage

• Make sure your project gets

approved

• Refresh data periodically to keep

your RCCP valid

Key Points


Project Tracking – Option 1

• Go to Capacity Tool website https://demandvisibility.cat.com/DemandVisibilityTool/IRCCPSummary.do

• Under “RCCP” select “iRCCP Summary”, input supplier code.

• View button will take you to the approved project Read Only mode

Security Override

• External suppliers will only have access to projects linked to their supplier code/codes

• Caterpillar users will have access to see all approved projects (Read only).

• Cycle time information will be hidden and only available for people linked to that project

https://demandvisibility.cat.com/DemandVisibilityTool/IRCCPSummary.do


Track Changes

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• For every refreshed project, capacity tool will provide a summary page of the high level information that was

updated with dates, user id and if change was performed by CAT or Supplier.

• You can find the changes summary at approval page, change log subpage.


Project Tracking – Option 2

• Go to Supplier Connect website https://supplierconnect.cat.com/wps/myportal/catconnect

• Under performance, select “Dashboard” , input supplier code, search for KPI “Capacity Management”

https://supplierconnect.cat.com/wps/myportal/catconnect


Reading KPI “Capacity Management”

▪ Capacity management will be used as the RCCP acceptance criteria for SQEP certification

▪ KPI will show the coverage as▪ DET (Detailed)

▪ INT (Intermediate)

▪ N/A (No evidence of RCCP data)

▪ The KPI thresholds will be


Reading KPI “Capacity Management”

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• Stoplight chart and Resource charts are displayed

• Hyperlinks to Capacity tool (DVT)

− "RCCP Type" Hyperlink will take you to approved Project

− Request RCCP will take you to "Request step"


Summary

1. Rough Cut Capacity Planning (RCCP) helps proactively identify and address any future capacity gap within supply base to ensure an executable production plan at Caterpillar facilities.

2. RCCP projects are stored at Capacity tool on demand visibility website

3. Capacity tool enables supplier to input capacity information, provides a live demand view and helps set up , document and track action plans.

4. After an RCCP Project is approved, information will be stored and copied for refreshed projects.

5. Approved projects on Capacity tool, serve as Capacity Management evidence for SQEP certification.

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rough cut capacity planning

Documents