Factory Capacity & Layout Audit Pro

Turn factory, warehouse, assembly-line, or packing data into a clear expansion decision.

Provide station cycle times, staffing, daily demand, and optional material-flow data. Get a decision-ready audit that identifies the true bottleneck, required capacity, and layout risks before you add labor, equipment, or floor space.

What you get

• Peak-day and P90 demand analysis
• Station-by-station capacity calculation
• Bottleneck ranking by utilization
• Required number of parallel stations
• Daily capacity gap and expansion decision
• Buffer-sizing checks
• Material travel-distance analysis
• Pedestrian / forklift aisle-crossing warnings
• A concise management-ready Markdown report

Best for

• Factory managers planning a new workstation
• Warehouse and packing operations with missed delivery targets
• Assembly lines with uncertain bottlenecks
• Operations consultants preparing a capacity review
• Teams deciding whether to add people, equipment, shifts, or floor space

How it works

1. Provide three simple CSV files:

   • stations.csv — cycle time, parallel stations, operators, uptime, and queue target
   • demand.csv — daily production demand
   • flows.csv — optional distances, buffers, and aisle conflicts

2. Run the included audit script.

3. Receive:

   • ADD_CAPACITY, MANAGE_RISK, or CAPACITY_OK
   • the current bottleneck
   • the number of parallel stations required at peak demand
   • the next bottleneck to protect after expansion
   • layout actions ranked by severity

Example decision

Decision: ADD_CAPACITY

Packing is operating at 123% utilization on peak demand and requires 2 parallel stations instead of 1. Before adding the station, resolve the undersized buffer and the forklift/pedestrian aisle crossing between assembly and packing.

Included files

• Reusable SKILL.md workflow
• Python capacity and layout-risk audit tool
• Ready-to-edit CSV templates
• Input schema reference
• Example data and automated test

Requirements

• Python 3.8 or newer
• No external Python packages
• Runs locally and works offline
• No API key or paid service required

Important note

This tool provides an operational screening audit. It does not replace detailed engineering, safety, fire-code, ergonomic, or regulatory review.