Falco CPC

What is Broken Today

In most manufacturing setups, production planning still relies on outdated Excel sheets or ERP tools that only factor in surface-level capacity. What gets missed are the very constraints that actually choke your throughput:

• Material delays
• Machine downtimes
• Absenteeism
• Waiting for customer approvals
• Overlapping schedules
• Unclear job priorities

The result? A constant cycle of overcommitments, firefighting on the shopfloor, and missed deliveries. Teams jump from one crisis to another, unable to step back and fix the root causes.

Why Traditional Capacity Planning Fails

Most ERPs calculate production capacity in a vacuum — assuming every machine, person, and process is always available. But in real life.

• Your star welder is out sick
• That CNC machine is under maintenance
• Raw material didn’t arrive
• A key drawing change is pending

Yet, your system still shows you have capacity. That illusion creates a dangerous gap between what’s planned and what’s actually possible. And the production team ends up catching the fallout.

Enter Falco CPC — Constraint-Based Production Planning

Falco CPC (Capacity Planning & Control) flips the logic. Instead of planning around ideal conditions, it plans with constraints in mind.

You can create your own master data for:

• Machine-hour costs
• Labour availability
• RM (Raw Material) stock
• Process costs
• Lead times
• Downtime patterns

CPC then runs a smart scheduler that factors in these constraints and gives you a realistic capacity plan — one that can actually be executed.

What Falco CPC Fixes

Once the order is in, Falco’s capacity planning engine kicks in:

• From Illusion to Reality:
  • Plans based on actual shopfloor conditions — not assumptions
• Bottleneck Visibility
  • See which constraint (machine, manpower, material) is blocking which order
• Smart Loading:
  • Load jobs based on delivery priority, current capacity, and order size
• Dynamic Reshuffling:
  • Auto-adjusts job loading as conditions change (e.g., if a machine breaks down).
• What-If Simulations:
  • Simulate multiple capacity scenarios before committing to a schedule
• Faster Decision-Making:
  • Eliminate trial-and-error. Your plan already knows what’s possible

For Planning Managers and Production Managers

Falco CPC is a game-changer for:

• Planning Teams:
  • Create grounded schedules that consider ground realities
• Production Managers
  • Know exactly what’s expected and what’s possible — no surprises
• Sales & Customer Teams:
  • Commit delivery dates with confidence

No more internal blame games. Everyone works on the same reality.

Seamless Integration with Falco OPS

Falco CPC integrates with:

• CEM: For real-time customer order tracking
• NPD & PCS: For coordination with product costing and engineering
• Admin Central: For access rights and delegation
• Pulse: To monitor real-time execution vs. plan

So, you’re not just planning better — you’re building an entire execution system around your reality.

Don’t Let Your Factory Plan in Fantasy Mode

Every shopfloor has constraints — but only a few plan with them in mind. Falco CPC brings realism, flexibility, and visibility into your planning system.
Let the firefighting stop.
Let the execution begin.