Demand peaks
Stress the arrival pattern instead of a single average weekly volume.
- Model demand peaks and mix
- Test typical and busy periods
- See when queues build
Capacity
planning.
Size for real demand. Know what the line can deliver.
We test stations, people, shifts, and machines against variation before you commit to the next capacity step.
The real challenges.
An average output target hides the peaks, stops, and shared resources that determine usable capacity. Explore five challenges using the cards or arrows below.
How simulation helps
Demand peaks
Station bottlenecks
Shifts & labor
Downtime & setups
Growth decisions
01 / 05
Station bottlenecks
Find the station that limits total output as demand changes.
- Trace work through the line
- Measure blocking and starvation
- Test the next capacity step
Shifts & labor
Model handovers, breaks, and shared operators across each shift.
- Represent real shift calendars
- Test operator coverage
- Compare workable shift options
Downtime & setups
Include breakdowns, maintenance windows, and product changeovers.
- Model machine availability
- Include setup sequences
- Test ways to recover lost time
Growth decisions
Test added capacity in stages to learn when each option is needed.
- Compare expansion options
- Find demand triggers
- Check the next constraint
Explore all five challenges · Select a card or use the arrows
The results.
A capacity study gives your team a defensible plan for the demand and operating conditions you expect.
Know usable capacity
See the output range the line can sustain across typical and peak conditions.
Find the real constraint
Identify what limits throughput now and what becomes limiting after a change.
Choose workable shifts
Compare staffing and shift patterns using the hours actually available to produce.
Prioritize investment
Test equipment, buffers, and operating changes before spending on more capacity.
Plan for growth
Know the demand level that should trigger each next capacity step.
What you take away
A working simulation model + Scenario comparisons + Engineering recommendations
Capacity planning consulting
Plan the next machine, shift, or expansion around the demand your operation must serve. We compare usable capacity and investment options before you commit.
Explore our simulation project supportCapacity additions and investment timing
Compare capacity additions in sequence, not only by machine count. We test your demand profile, identify the station or shared resource limiting output, and re-run each proposed addition. Findings show which constraint moves next and the volume that should trigger each step.
Shift patterns and usable production hours
An added shift provides hours, but useful output depends on handovers, setups, maintenance, and available labor. We compare the proposed shift pattern with alternatives, such as added capacity across existing shifts, using the same demand and realistic operating losses.
Peak-demand resilience
Stress-test the arrival pattern with its peaks intact. We increase demand and vary product mix to see where stations, staging, buffers, or shared operators stop coping. The result is a set of operating limits rather than one nominal capacity figure.
A study built around your operation
The study starts with your output target, planned demand range, and candidate investments. We agree which line or network to model and include the shared labor, material supply, and downtime that determine usable capacity.
Inputs for a credible comparison
Typical inputs include demand by period and product, cycle-time distributions, setup sequences, machine availability, staffing calendars, and buffer capacities. We check assumptions against the current line before comparing capacity options.
Findings for your next decision
Depending on scope, receive a working model, bottleneck and utilization analysis, and capacity scenarios compared on identical demand. Findings show the next limiting resource and the demand level that should trigger each investment.
Turn capacity uncertainty
into a workable plan.
With expert simulation consultation.
Tell us the demand and investment decision you are weighing. We’ll explore what a capacity study should test.