Work center utilization
Load as a share of regular capacity. Amber is tight, orange needs overtime, red is beyond overtime and goes to a subcontractor or stays unbuilt. Click a cell to chart that work center.
Load vs capacity
Hours by work center
Totals across the plan horizon. Station hours are machine or bench time; labor hours multiply by the crew on each station.
Monthly manufacturing cost
Material dominates electronics cost, so conversion cost (labor, overtime, subcontract, overhead, carrying) is shown by default.
Cost bridge, baseline to scenario
Each bar applies one group of your changes in turn, so the steps add up to the total difference.
What moves cost most
Each driver moved down and up on the current scenario, holding everything else.
Cost summary
Plan horizon totals, scenario against baseline.
Headcount needed vs staffed
Full-time equivalents needed each month (regular plus overtime labor hours divided by one person's productive shift hours, after efficiency losses), against the roster implied by stations, shifts and crew. Red cells need more people than are staffed.
Labor cost by work center
Regular pay includes burden and shift premiums. Overtime carries its premium plus payroll taxes.
Pick a product to see its routing, build time and cost.
Work centers
Capacity is stations × shifts × hours per shift × working days × efficiency. Crew is people per station. Cells that differ from the baseline are highlighted.
Sourcing and standard routing by category
Make or buy, bill-of-material cost as a share of price, contract manufacturer price for bought categories, and standard run minutes per unit at each work center. Individual products vary around these standards.
Scenario comparison
Baseline, your current inputs and every saved scenario side by side. Saved scenarios stay in this browser.
How the model works
Demand
Starts from the monthly unit plan for each product, summed across warehouses. A seasonality profile keeps each product's total over the horizon and redistributes it across months: units = average × (1 + (index − 1) × intensity), rescaled so the horizon total is unchanged. Volume change and a one-month event are applied after.
Production schedule
- Chase builds each month's demand in that month.
- Level builds at the lowest constant rate that never falls behind cumulative demand.
- Pre-build starts from chase, works backward from the last month and moves volume above regular capacity into earlier months with spare room, up to the window you set.
Stock built ahead of demand is charged at the carrying rate on its material plus labor value.
Hours
Each product has a routing with run minutes per unit and setup hours per run at five work centers. station hours = units × run minutes ÷ 60 × (1 + rework) × productivity factor + runs × setup hours. Productivity compounds monthly from the annual rate. Labor hours = station hours × crew.
Capacity
Working days are counted from the real calendar for the days per week each work center runs, minus plant holidays placed in the months they usually fall. regular capacity = stations × shifts × hours per shift × working days × efficiency. Overtime is capped by your limit and by the hours physically left in the month. Anything beyond overtime is subcontracted or left unbuilt.
Cost
- Material = units built × price × bill-of-material share × (1 + scrap), with inflation from its effective month.
- Regular labor = labor hours × rate × (1 + wage increase after its effective month) × (1 + average shift premium) × (1 + burden).
- Overtime = overtime labor hours × rate × (1 + premium) × 1.10 for payroll taxes.
- Subcontract = overflow station hours × (in-house loaded labor plus variable overhead per hour) × subcontract multiplier.
- Variable overhead = station hours × rate per hour (power, consumables, maintenance).
- Fixed overhead = stations × monthly cost per station + supervision per shift + plant fixed cost.
- Headcount needed = (regular + overtime station hours) × crew ÷ (hours per shift × working days × efficiency).
- Contract manufacturing = units × price × contract price share, for bought categories.
Unit cost allocates each work center's monthly cost to products by their share of that work center's station hours in that month. Fixed cost not absorbed in a month is spread by total station hours.
Bridge and sensitivity
The bridge applies your changes in groups, in this order: demand, strategy, operations, productivity, labor, materials. Sensitivity moves one driver at a time on the current scenario, holding everything else.