Capacity planning with congestion effects

Important operational performance measures for a successful firm include not only price and quality, but also fast and on time delivery of customer orders. Capacity is a key issue in determining the lead time from customer order to delivery. However, capacity planning models seldom consider the impact of capacity levels on lead time performance. An important characteristic of this paper is the incorporation of congestion effects and their impact on lead time in making capacity acquisition decisions. It is especially important in a make-to-order environment, where customer orders arrive randomly and lead to high variability and congestion. This work was motivated by our observations of such tradeoffs at firms in several industries. We present a model to make equipment choice decisions in a multi-product, multi-machine, and single-stage production environment with congestion effects. The model is a nonlinear integer program. We present a heuristic solution procedure for this problem, which is based on a lower bound for the formulation that can be solved efficiently. The computational study shows that the solution procedure is quite effective in solving industry size problems. We illustrate the application of the model using data from a chemical-testing laboratory. We also discuss various extensions of the model.