PT. XYZ, a growing windshield manufacturer, faces a significant production
capacity deficit, leading to an unsustainable reliance on costly overtime to meet
demand surges driven by e-commerce promotions. This research aims to improve
the company's capacity planning by implementing a formal Rough Cut Capacity
Planning (RCCP) framework to analyze the problem and evaluate strategic
solutions. The methodology involved developing a Causal Regression model,
which was validated as the most accurate forecasting tool with a Mean Absolute
Deviation This forecast was used to create a "pulsed" Master Production Schedule
(MPS). An RCCP analysis was then performed using a scaled Bill of Labor
Approach (BOLA), which quantitatively proved a significant capacity deficit. An
evaluation of alternatives, including overtime and adding new machinery, revealed
that no single strategy is a complete solution. The research concludes that the most
effective solution is a hybrid strategy: a primary investment in a new machine to
address the fundamental capacity shortage, supplemented by the use of planned
overtime to manage the remaining absolute peak demand.
Key words: RCCP, forecasting, Causal regression, MPS, BOLA