Work Centers for CAPA

A Work Center is the physical place (or logical grouping) where work happens — a press line, a folder station, a cutting bench. ianaiERP's original Work Center already powered routings and work orders. The EMS + CAPA suite extends it with the parameters needed to compute realistic capacity, model planned and unplanned downtime, and decide which work centers belong in the nightly capacity snapshot.

This page covers the new CAPA-specific fields added to Work Centers. For the original Work Center fields (name, cost rates, location, line items, calendars), see the advanced Work Center docs.

Where it lives

• List + create: /workcenter
• Edit: click any row to open the drawer.
• Permission: needs support_read to view and support_write to edit (same as the original Work Center page).

The CAPA fields

When you open the Work Center form (+ New Work Center), you'll see a Capacity Parameters section. These five fields are the inputs the nightly CAPA cron uses to project utilization, ETAs, and overload.

Machine Speed (machine_speed_per_hour)

The work center's nameplate throughput per hour, in the WC's natural production unit (sheets/hr, kg/hr, units/hr — your call). Used as a sanity check against routing operations and as a fallback when a routing operation doesn't define a runtime_per_unit.

• Leave blank if the WC's output varies wildly by product (rare).
• Use the nameplate — efficiency is modeled separately via OEE.

Rated Hours / Day (rated_hours_per_day)

The number of hours per day this WC is physically able to run, independent of staffing. A 24-hour press has 24. A bench used during one shift has 8. Combined with Shift Pattern below to compute calendar minutes.

Shift Pattern (shift_pattern)

A canonical operating cadence:

The picker shows a warning if your Rated Hours / Day significantly exceeds the shift pattern's expected hours — it's not blocking (you may have overtime or unusual cadences), but it flags likely data-entry mistakes.

OEE Target (oee_target_percent)

Your planning OEE factor — the percentage of calendar time you realistically expect to convert into output, after losses for changeovers, micro-stops, quality, and minor breakdowns. This is not measured OEE — v1 doesn't compute that. It's the planning factor the capacity calculation multiplies against.

• Typical range: 60–85 for manual operations, 85–95 for automated equipment.
• Use 100 only if you genuinely have no historical losses (rare; the calc will be optimistic).

Availability (availability_percent)

Expected availability after planned downtime (maintenance windows, scheduled outages). Multiplied against calendar minutes before OEE.

• Typical: 90–95.
• This is conceptually different from OEE (which captures all losses); set it conservatively for WCs with frequent PM windows.

Default Setup (default_setup_minutes)

Default changeover used by the capacity calc when a routing operation doesn't specify its own setup time. Also used as a changeover penalty when the calc switches from one item to another in the same WC.

Critical for CAPA dashboard (critical_for_capa)

Toggle that decides whether this WC is included in:

• The nightly CapaSnapshot cron (every 24 hours at 02:00).
• The 5-minute rollup that recomputes the WC's current_runtime_status from its child assets.
• The Equipment Hub's CAPA-related KPIs (Utilization, OEE, WCs at Risk).

A WC with critical_for_capa = false still appears in the Capacity Planner (you can recompute it on demand), but it doesn't drive automatic alerts or dashboard KPIs.

Read-only computed fields

These show on the form once the WC has data:

How CAPA uses these fields

calendar_min = ratedHoursPerDay × daysInPeriod × 60   (capped by shift_pattern)
calendar_min × (availability_percent / 100)            → available_minutes
available_minutes − planned_PM_overlap_minutes         → still available
available_minutes × (oee_target_percent / 100)         → effective_minutes
sum(routing_ops × runtime_per_unit × qty + setup)      → demand_minutes
demand_minutes / effective_minutes × 100               → utilization_pct
demand_minutes − effective_minutes  (if > 0)           → overload_minutes

Risk level is bucketed:

• NONE if util < 85
• LOW if util 85–99
• MEDIUM if util 100–119
• HIGH if util ≥ 120

See Capacity Planner → How utilization is computed for the full algorithm including material-bottleneck adjustments.

Setup recipe (typical paper-packaging plant)

The Press Line A is the bottleneck — high speed, continuous operation, conservative-but-realistic OEE, critical-for-CAPA flagged. The bench is non-critical because it doesn't gate production.

Assigning assets to a Work Center

A Work Center is a logical grouping; its Assets are the physical machines that live inside it. From the Asset form, set work_center to the parent WC. The WC's status board on the Equipment Hub then shows all linked assets together. See Asset Management → Link to a Work Center.

Troubleshooting

Related

• Asset Management — link assets to work centers
• Capacity Planner — view computed snapshots
• Runtime Status — how the WC's current_runtime_status rolls up from assets
• Original Work Center reference: Work Centers (advanced features)