100% booked is not 100% healthy
Production plans need room for rework, rush orders, maintenance, training, setup variation and jobs that stitch slower than the weekly average.
Separate normal runway from peak runway
A shop can be comfortable in March and structurally short in November. Model both normal demand growth and the peak multiplier that applies to your real season.
Measure good capacity
Use completed, sellable pieces rather than theoretical head-hours. If actual weekly capacity already includes typical thread breaks and rework, it is a much better planning input than brochure speed.
Trigger quote research before the crossing point
Equipment research, financing, delivery, installation and training all take time. The useful upgrade date is earlier than the week demand exceeds capacity.
Forecast the crossing