ProFactory Operations & ProductivityCapacity

Order Acceptance Under a Binding Constraint

Once capacity binds you are not selling garments, you are selling hours. The best order on the book is often the one to refuse.

The Constraint

One resource, the one that runs out first

On the constrained resource over the period, after downtime and absence

The Order Book

Variable cost means the cost that would not be incurred if the order were refused - materials, piece rate, and the consumables that go with them. Absorbed overhead does not belong here and putting it in is what makes a fast cheap order look unprofitable. Minutes per piece are minutes on the constrained resource only, not the total work content: an order that spends a long time somewhere with spare capacity is not expensive in the only currency that is short.

OrderPieces pcsPrice cost/pcVariable Cost cost/pcOn the Constraint min/pcContribution costHours hPer Hour cost/hMargin %Rank by Hour no.Rank by Margin no.Accept 1/0Margin Rule Takes It 1/0Price to Earn Its Hours cost/pcRefused on Rate 1/0Refused on Fit 1/0Row actions
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Add line opens a form. Cells in the sheet stay directly editable.

How to read this sheet

The whole sheet depends on one claim: that a single resource is what runs out. Where two resources bind on different orders - stitching on one, finishing on another - the ranking here is not the answer and no single ranking is, because the problem stops being a ranking and becomes an allocation across two scarcities. The honest use is to identify the resource that binds first, rank against that, and re-run when it moves, which it does between seasons. Whole-order selection is a knapsack, and taking orders in rank order is not guaranteed to be the best possible set: an order skipped because it does not fit can leave hours nothing else fills. Idle hours are therefore reported for both rules rather than assumed away, and where they are large the remedy is usually to ask a buyer whether a delivery can be split rather than to accept the sheet's answer. The price at which a refused order would earn its hours is the rate of the worst order still accepted, applied to that order's minutes - it is a negotiating position, not a valuation, and an order can clear it and still be refused because it does not fit, which the sheet distinguishes because the two have different remedies. Fixed cost is absent deliberately: it does not change with the decision, and absorbing it per piece is what makes a fast cheap order look unprofitable. Nothing here values the customer relationship, the cost of refusing a buyer whose other programmes you keep, or the learning curve on a repeat style - and the first of those reverses real decisions that this arithmetic would settle the other way.

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