Best practices for calculating remaining (food) manufacturing capacity?

Evaluating remaining food manufacturing capacity is crucial for assessing scalability and potential bottlenecks. Here’s a structured approach based on best practices: 1. Define Key Capacity Metrics To determine remaining capacity, first establish the key metrics: Production Line Capacity (units per hour or pounds per shift) Batch Processing Capacity (batch size and cycle time) Shift Utilization (current shifts vs. maximum possible) Equipment Utilization (OEE – Overall Equipment Effectiveness) Facility Constraints (storage, refrigeration, space availability) 2. Calculate Current Utilization Assess the actual production levels relative to maximum capacity: Utilization Rate = ( Actual Output Maximum Theoretical Output ) × 100 Utilization Rate=( Maximum Theoretical Output Actual Output ​ )×100 For example, if a line can produce 1,000 units per hour but is running at 750 units per hour, its utilization is 75%, leaving 25% headroom. 3. Identify Constraints Even if machinery has additional capacity, other factors can limit output: Labor Availability: Can more shifts be added? Ingredient Supply: Are raw materials scalable at higher volumes? Storage & Logistics: Can warehousing and distribution handle more inventory? Regulatory Compliance: Are there permitting or food safety constraints? 4. Conduct a Bottleneck Analysis A bottleneck in a single stage (e.g., packaging, cooking, cooling) can limit the entire line’s output. Use tools like: Theory of Constraints (TOC): Identify and alleviate the slowest process. OEE Analysis: Break down availability, performance, and quality losses. 5. Evaluate Expansion Scenarios Incremental Capacity Gains: Can minor tweaks (e.g., shift extensions, automation) increase output? CapEx Investment: What would be required to scale production (e.g., adding a second line, upgrading ovens)? Seasonality Factors: Is peak season utilization already near full capacity? 6. Run Sensitivity Analysis for Growth Model different demand scenarios and assess how quickly the facility reaches full capacity. For example: 10% increase in demand: Can the current setup absorb it? 20-30% growth: Would new equipment or additional shifts be required? 7. Validate Data with Site Visits & Interviews Numbers from financials might not reflect actual constraints. Speak with: Production managers (real-world bottlenecks) Shift supervisors (downtime, inefficiencies) Supply chain teams (raw material sourcing challenges) Would you like help structuring a simple model for capacity calculations?

I dont know your situation but i've done capacity model for hundreds of platforms running multiple processes one a single platform. If you can get a grasp of you utilization in *hours per week* first it will be easy to build up from there. feel free to DM if you want to walk through your scenario.