Capacity and Resource planning 

Reacting flexibly to short-term fluctuations in demand for long-term success.

Transparent approach

Volatility and dynamics of the markets as a challenge in capacity and resource planning

The volatility and dynamics of the markets are a major challenge in terms of capacity and resource planning. The planning tools implemented in the company often do not provide comprehensive support.

However, capacity and resource planning is an important basis for many other operational and strategic decisions at the location and network level. In addition to the dimensioning of factories and factory buildings, investment and personnel decisions are made in the medium term based on capacity and resource planning. In the short term, it represents the basis for production planning and control as well as personnel deployment planning.

We will support you with capacity and resource planning

  • Strategic capacity planning
  • Synchronous capacity planning in the network
  • Investment and personnel planning
  • Series start-up, ramp up and ramp down
  • Flexibility of capacities
  • Workforce management/personnel deployment planning

Strategic capacity planning

Long-term decisions are made with strategic capacity and resource planning. It forms the basis for CapEx decisions on establishing or expanding locations and is part of every factory planning. 

Synchronous capacity planning in the network 

Do you see opportunities to leverage synergy effects in the network and to increase overall utilization and efficiency? However, isolated solutions have been created in your network that do not make it possible to create comprehensive planning? We will work with you to develop a continuous, cross-departmental planning and control process and provide you with the right tools and methods.

Investment and personnel planning

In the medium term, the resources in terms of machines and personnel will be defined through investment decisions and personnel planning within the framework of budget planning. As part of the planning, in addition to the utilization in the current concept with which your PPS system supports you, you should also take into account the adaptation of the production processes (e.g. adaptation of the working time model and change in the assembly organization – keyword flow principle) and the effects on the OpEx. 

Successful launch of series production, ramp up and ramp down

Is the demand for your products increasing by leaps and bounds? Is the launch of a product pending? Is the space efficiency decreasing due to the ramp-down? Then you should urgently adjust the capacities. We support you with the planning and help you implement suitable measures for the (temporary) adjustment of your capacity. 

Flexibility of capacities

We will show you which measures you can use to make your capacity more flexible to respond to volatile demand at short notice. Personnel deployment, machines, maintenance, make or buy: together, we will define a suitable setup to increase your flexibility.  

Workforce management/personnel deployment planning

The goal is to have the right employees at the right place of work at the right time. We support you in establishing the right processes, creating the organizational structures, selecting a suitable IT system environment, and implementing it if necessary.

Challenges in the area of capacity and resource planning in practice

Practical questions in capacity and resource planning
  • Which capacities have to be kept available in the next few years?
  • Which areas, personnel capacities and machines are required?
  • To what extent should flexibility and adaptability be taken into account?
  • Which capacities and investments in resources and technologies should be taken into account in the next budget planning?
  • How can continuous planning be mapped with increasing volatility in demand and changing requirements?
  • What impact does the change in capacity have on relevant KPIs and OpEx?
  • What proportion of the required capacity should be available internally?
  • What flexibility models are there? To what extent should external capacities be used?

With foresight to long-term success

to react flexibly to short-term fluctuations in demand

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Increase planning horizon

We know that long-term forecasting (> 5 years) is a big challenge. But would you plan a new factory without foresight? Factory planning is our hobby. We support you in aggregating existing information, assessing risks, avoiding mistakes by others and thus generating sustainable capacity planning for the future.


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Use practical experience across industries 

We know the stumbling blocks in reality and help you to flexibly implement short-term capacity changes. We have already implemented numerous capacity increases in practice and understand what is important on the shop floor.


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Tools and methods

You are using an ERP system, but the resource planning does not match reality? Our consultants support you with the right tools and methods to generate transparency and develop the right approach for your task, if necessary, considering future-proof software solutions.


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Cooperation and knowledge transfer 

We live in a cooperative project mode. We work out the project result together with you and gradually transfer method and tool competence to build up your necessary knowledge internally.  

Success factors

Success Story 

ifp consulting supports an international group during the Covid-19 pandemic with the short-term increase in capacity by a factor of 5. The aim was to temporarily increase the existing capacities significantly. To this end, the appropriate measures were developed based on extensive medium-term capacity planning, and continuous personnel deployment planning was established. By adapting the working time model, establishing training concepts for qualification and adapting the workplace design, among other things, by introducing the flow principle, not only was efficiency increased but compliance with the AHA rules was also supported and the target achieved by the end of the year.

Kapazitäts- und Ressourcenplanung
Accompanying services

  • Factory planning
  • Ramp Up Management
  • S&OP process
  • Network optimization
  • Production footprint
  • Production control
  • Increase in system efficiency
  • Ideal vertical range of manufacture
  • Assessment & benchmarking

Capacity and resource planning

Take away

Capacity and resource planning is an indispensable part of every company. Reliability of the results, adaptivity of the methodology, and transparency of the procedure are important factors that should be considered in a comprehensive capacity and resource planning.

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