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Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?
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Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?
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  Post Number #1  
Old 10th June 2012, 08:18 AM
samsung's Avatar
samsung

 
 
Total Posts: 1,431
Question Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

What does 'design capacity' (or 'rated capacity') mean and what factors does the manufacturer take into consideration while declaring the 'design capacity' of the equipment?

e.g. if the manufacturer has expressed the design capacity of a plant as 6000 tons per day, is it equivalent to 2.19 million tons per annum given the fact that the equipment does require scheduled maintenance and also there are unplanned downtime, delays, max. process efficiency and various other factors that could adversely affect the actual production capacity.

In short, what I'm interested to know is how to determine the annual production capacity if the designed capacity is expressed in tons per day or tons per hour.

Thanks in advance for your valuable inputs.

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  Post Number #2  
Old 10th June 2012, 08:34 AM
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Total Posts: 579
Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Overall Equipment Effectiveness(OEE) which is a combination of Utilization, Efficiency and Quality will play a role in deciding actual capacity. Normally when a Manufacturer claims his Capacity, it is better to get into the details of whether OEE is taken into account or otherwise.
  Post Number #3  
Old 10th June 2012, 11:37 AM
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Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Quote:
In Reply to Parent Post by samsung View Post

What does 'design capacity' (or 'rated capacity') mean and what factors does the manufacturer take into consideration while declaring the 'design capacity' of the equipment?

e.g. if the manufacturer has expressed the design capacity of a plant as 6000 tons per day, is it equivalent to 2.19 million tons per annum given the fact that the equipment does require scheduled maintenance and also there are unplanned downtime, delays, max. process efficiency and various other factors that could adversely affect the actual production capacity.

In short, what I'm interested to know is how to determine the annual production capacity if the designed capacity is expressed in tons per day or tons per hour.

Thanks in advance for your valuable inputs.
Design capacity is the design input of safe maximum limit per unit time. This unit time may be cycle dependent of the equipment. For example a STP capacity can be in CMD (cubic meters per day), For a blower it can be in CFM (cubic foot per minute) For a EOT it can be SWL (Safe working load) for a water filter system, it can be LPM (Litre per minute)
The usage can be played around this capacity but cannot be expected to perform to extrapolated time to annual levels. This will be just one factor alongside several other to determine or plan annual capacity.
  Post Number #4  
Old 10th June 2012, 12:15 PM
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samsung

 
 
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Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Thanks for the responses.

I put up my question in another way -

Design capacity = 6000 tons per day

Annual capacity = 6000 x 365 or 2190000 tons

Assuming 35 days for preventive maint. and other unplanned downtime,

So the actual production would be = 6000 x 330 or 1980000 tons

Can the design capacity be calculated as = 2190000/330 or 6636 tons per day ?
  Post Number #5  
Old 10th June 2012, 12:22 PM
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Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Quote:
In Reply to Parent Post by samsung View Post

Thanks for the responses.

I put up my question in another way -

Design capacity = 6000 tons per day

Annual capacity = 6000 x 365 or 2190000 tons

Assuming 35 days for preventive maint. and other unplanned downtime,

So the actual production would be = 6000 x 330 or 1980000 tons

Can the design capacity be calculated as = 2190000/330 or 6636 tons per day ?
Design capacity is never deduced from production capacity. Rather production capacity is factored over design capacity.
  Post Number #6  
Old 10th June 2012, 12:28 PM
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samsung

 
 
Total Posts: 1,431
Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Quote:
In Reply to Parent Post by somashekar View Post

Design capacity is never deduced from production capacity. Rather production capacity is factored over design capacity.
Do you mean Capacity utilization,

Utilization = Actual output / Design capacity

In this case, it would come out to be 110.6%
  Post Number #7  
Old 10th June 2012, 01:07 PM
somashekar's Avatar
somashekar

 
 
Total Posts: 5,364
Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

No. I used the word factored and not calculated.
Design capacity is a constant. Moreover a management decision to install a higher design capacity equipment can be taken with future in mind. This capacity cannot be governing utilization.
Quote:
Utilization = Actual output / Design capacity
Denominator is a constant, so utilization is directly proportional to output. I cannot know from where you get this equation.
  Post Number #8  
Old 12th June 2012, 11:07 AM
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Chennaiite

 
 
Total Posts: 579
Re: Design Capacity - What does 'Design Capacity' (or 'Rated Capacity') mean?

Quote:
In Reply to Parent Post by samsung View Post

Thanks for the responses.

I put up my question in another way -

Design capacity = 6000 tons per day

Annual capacity = 6000 x 365 or 2190000 tons

Assuming 35 days for preventive maint. and other unplanned downtime,

So the actual production would be = 6000 x 330 or 1980000 tons

Can the design capacity be calculated as = 2190000/330 or 6636 tons per day ?
Here's my understanding.
Assuming that there is only one Equipment involved, lets say the Utilization of the Equipment is 90%, Efficiency is 90% and Quality is 100%. Overall Equipment Effectiveness is 90X90X100 i.e. 81%. Now your actual capacity would be 6000X0.81 i.e. 4860 tons per day or 1773900 tons annual.

Remember, Utilization is not just about Preventive Maintenance and Unplanned downtime, it also includes Daily Meeting, 5S, Setting time, etc. Efficiency of the equipment is another important factor in Capacity calculation. The theoretical Cycle time can be 1 min/part, but after one hour of continuous operation the equipment may yield only 45 parts (with 75% efficiency). And number of bad parts produced, all these decide the actual capacity.
Thanks to Chennaiite for your informative Post and/or Attachment!
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