Capacity SheetProcess Capacity Sheet
Standardized Work Form 1
What is a Process Capacity Sheet?
The Process Capacity Sheet is Form 1 of the three standardized work documents. It calculates the true production capacity of each machine in a process sequence. By documenting manual time, auto time, completion time, and tool change requirements, you can identify which machine is the bottleneck — the constraint that limits the entire line's output.
| Step | Step Name | Machine # | Basic Time (sec) | Tool Change | Capacity / Shift | Remarks | ||||
|---|---|---|---|---|---|---|---|---|---|---|
| Manual | Auto | Completion | Parts / Chg | Time | ||||||
| 1 | 721p | |||||||||
| 2 | 1,430p | |||||||||
| 3 | 716p | |||||||||
| 4 | 2,300p | |||||||||
| 5 | — | |||||||||
| 6 | — | |||||||||
| 7 | — | |||||||||
| 8 | — | |||||||||
| 9 | — | |||||||||
| 10 | — | |||||||||
| Total | 28 | |||||||||
Available time is typically 27,600 sec (460 min) per 8-hour shift with breaks.
The changeover time is amortized across each piece in the lot, increasing the effective time per piece.
Everything is editable — click any field.
Want an editable copy?
Download the free Process Capacity Sheet template — the same form with the capacity and bottleneck formulas pre-built, plus a worked machining-line example. Opens in Excel and Google Sheets.
What is a Process Capacity Sheet?
The Process Capacity Sheet (PCS) — Form 1 of the three core standardized work documents — answers a fundamental question: can we actually make enough parts to meet customer demand? For each machine or process step, it calculates the maximum number of parts that can be produced in a shift, accounting for manual time, auto time, and tool change frequency.
The process with the lowest capacity is the bottleneck. Knowing the bottleneck before building the Standardized Work Combination Table prevents wasted effort — there is no point balancing work across operators if a single machine cannot keep up with takt.
When to use this tool
Complete the PCS before any other standardized work document. It is especially important when introducing new products, changing takt time, or investigating chronic shortages. The capacity data also feeds into OEE calculations by quantifying the gap between theoretical and actual output. A free process capacity sheet template for Excel is available from the download button above — the same form with the capacity and bottleneck formulas pre-built.
Related tools
- Standardized Work Combination Table — Form 2: balance work elements against takt time
- Standardized Work Chart — Form 3: map the physical layout and operator path
- Time Observation Sheet — gather the manual and auto time data the PCS needs
- Takt Time Calculator — calculate the demand rate to compare against capacity