07PlanAI · Lumora Consumer ProductsDemo Data
Capacity & Constraints
Identify bottlenecks before they impact service.
Intelli AI Capacity Summary
Week 6 bottleneck is not mixing and not packaging material — it is Filling Line 2: 99 hrs required vs 104 available (gap -4 hrs).
Capacity heatmap
Utilization by plant / line / week · click a cell
< 55%Healthy85–93%93–100%> 100%
| Plant / Line | W1 | W2 | W3 | W4 | W5 | W6 | W7 | W8 | W9 | W10 | W11 | W12 | W13 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Westport · Mixing Vessel 1 | |||||||||||||
| Westport · Mixing Vessel 2 | |||||||||||||
| Westport · Filling Line 1 | |||||||||||||
| Westport · Filling Line 2 | |||||||||||||
| Southbay · Mixing Vessel 3 | |||||||||||||
| Southbay · Filling Line 3 | |||||||||||||
| Northgate · Soap Line 1 | |||||||||||||
| Northgate · Soap Line 2 | |||||||||||||
| Northgate · Lotion Line | |||||||||||||
| Riverbend · Detergent Line 1 | |||||||||||||
| Riverbend · Detergent Line 2 | |||||||||||||
| Eastfield · Packing Line |
Capacity waterfall — Filling Line 2, W6
Calendar → available → effective hours
Effective capacity
104 h
Required
99 h
Gap
-4 h
Headroom
Bottleneck analysis — W6
Not
Mixing Vessel 1
93 / 106 h
gap -13 h
YES
Filling Line 2
99 / 104 h
gap -4 h
Not
Packing Line
69 / 101 h
gap -32 h
Not
Packaging material
Maintenance event — Westport Line 2 unavailable 4 days (W5)
Capacity options
Each applies to the live plan
| Option | Capacity recovered | Cost | Service impact | Inventory impact | Risk | |
|---|---|---|---|---|---|---|
| Overtime | 12 hrs/wk | $222K | +1.2 pts | — | Fatigue | |
| Weekend Shift | +16 hrs/wk | $96.0K | +1.6 pts | — | Labor | |
| Alternate Line | Southbay FL3 | $26.0K | +1.4 pts | — | Low | |
| Alternate Plant | Southbay | $31.0K | +1.4 pts | +1 day transit | Low | |
| Reduce Changeovers | -4/wk | $7.5K | +0.8 pts | +cycle stock | Low | |
| Move SKU | Repair → FL3 | $18.0K | +0.5 pts | — | Low | |
| Prebuild Inventory | W3–4 idle hrs | $22.0K | +1.8 pts | +2 wks | Shelf life | |
| Subcontract | 40K units | $64.0K | +0.9 pts | — | Quality | |
| Defer Low-Priority Production | 1 campaign · 4 days | $0 | -0.3 pts low-prio | - | Customer |
Line capacity table
| Line | Plant | Type | Rate | Effective h/wk | Avg util | Peak | Changeovers/wk |
|---|---|---|---|---|---|---|---|
| Mixing Vessel 1 | Westport | Mixing | 2.4K/h | 106 | 82% | 89% | 6 |
| Mixing Vessel 2 | Westport | Mixing | 1.5K/h | 106 | 78% | 82% | 6 |
| Filling Line 1 | Westport | Filling | 5.9K/h | 104 | 85% | 88% | 10 |
| Filling Line 2 | Westport | Filling | 11.6K/h | 104 | 91% | 97% | 14 |
| Mixing Vessel 3 | Southbay | Mixing | 1.5K/h | 106 | 65% | 66% | 6 |
| Filling Line 3 | Southbay | Filling | 5.2K/h | 104 | 75% | 76% | 10 |
| Soap Line 1 | Northgate | Soap | 11.9K/h | 96 | 76% | 77% | 8 |
| Soap Line 2 | Northgate | Soap | 7.2K/h | 96 | 71% | 72% | 8 |
| Lotion Line | Northgate | Lotion | 2.9K/h | 96 | 82% | 82% | 8 |
| Detergent Line 1 | Riverbend | Detergent | 2.7K/h | 107 | 83% | 92% | 8 |
| Detergent Line 2 | Riverbend | Detergent | 1.9K/h | 107 | 75% | 75% | 8 |
| Packing Line | Eastfield | Packing | 4.1K/h | 101 | 68% | 69% | 10 |