The Master Scheduling Process

Master Scheduling Process

·         Develop build schedules for specific products

·         Master Production Schedule is the output to this process

o   MPS:  set of planning numbers that drive detailed scheduling and planning

 

 

Master Scheduling

Sales Operations Planning

Objective

Anticipated build schedule

Supply Rate

Item Planned

End Item/Planning BOM

Product Family

Constraints

Critical workcenters

Capacity

Planning Horizon

Longest Cumulative Lead Time

Longest Resource/Plant LT

Time Periods

Daily/Weekly

Monthly

Planning Focus

Product Mix

Product Volume

Process Output

Master Production Schedule

Production Plan

 

 

Relation to Master Planning of Resources

·         Production plan is how much needs to be produced by month of a product family

·         The Master Production Schedule breaks down that month by week and quantities per individual product

 

Master Scheduling Applications

·         MPS development

·         Projects backlog/inventory levels

·         Order Promising

·         Drives detailed scheduling/planning

·         Helps assign priorities

·         MPS IS NOT A FORECAST!

 

Master Scheduling Process

1.       Develop preliminary MPS

2.       Evaluate MPS using RCCP (Rough-Cut Capacity Planning)

3.       Revise MPS

4.       Re-evaluation of MPS using RCCP

5.       Publish MPS

 

 

Master Scheduling Process vs. Master Production Schedule

·         Master Scheduling process creates the Master production schedule

 

Inputs to the master scheduling process

·         Detailed Forecasts

·         Production plan from S&OP

·         Inventory/backlog targets

·         Time fence policies

·         Interplant/intraplant orders

·         Customer orders

·         Service parts forecasts/orders

·         Distribution requirements

·         Planning bills of material

·         Actual production/supply levels

 

Outputs from Master Scheduling Process

·         MPS

·         Projected Finished Goods inventory levels for Make-to-stock items

·         Projected Sub-Assembly inventory levels for Assemble-to-order items

·         Projected Finished Goods backlog levels for Make-to-order and Engineer-to-order items

·         Order Promising info

·         Product availability info

 

 

Projected available balance:

·         First Period

o   PAB = Current on-hand quantity + MPS – Customer Orders

·         After first period but before demand time fence

o   PAB = Prior Period PAB + MPS – Customer Orders

·         After Demand Time Fences

o   PAB = Prior Period PAB + MPS – (Greater of Forecast or customer orders)

 

Available to Promise:

·         Non Cumulative First Period

o   ATP = On-hand balance + MPS – Sum of customer orders before next MPS

·         Non-Cumulative All future periods that contain an MPS planned receipt

o   ATP = MPS – Sum of customer orders before next MPS

·         Cumulative First Period

o   ATP = On- hand quantity + MPS receipt quantity – Customer Orders in this period

·         Cumulative All other periods

o   ATP = Previous Period’s ATP + MPS receipt quantity – Customer orders in this period

·         Look Ahead (Backward ATP)

o   If period 1 has an ATP of 2 and the next two period’s demand create a negative ATP of 2 units in period 2, then the necessary quantity of 2 units would be “borrowed” from current period.  Zeros out the ATP for each period.

 

Types of bills of material used in master scheduling

·         Modular BOM

o   Options for customized products (Dell Computer)

·         Common Parts BOM

o   Common components that can be sold with different models of a product (regular, deluxe, or heavy-duty gas ranges)

o   Kitting Bill:  subset of common parts bill because involves small parts for assembly/installation (e.g. garage door and opener)

·         Super BOMS

o   Most widely used BOM

o   Catalog number is made up of abbreviated characteristics/components of end item

o   Each option for each component in BOM is given a percentage of how often it’s usually chosen

 

Advantages of Planning Bills

·         Reduced # of end items: items not assembled until demanded

·         Increased forecast accuracy:  higher product family level

·         Facilitates order entry (configurator)

·         Increased scheduling and planning accuracy:  MPS at the component level, FAS at finished goods level, less FGs and better customer service

·         Permits two-level scheduling

·         Increased computer processing flexibility/efficiency

 

Master Scheduler Responsibilities

·         Understand forecasting process

·         Manage supply constraints

·         Participate in S&OP

·         Monitor consistency in production plan

·         Create/upkeep MPS

·         Execute policies:  Time fences, safety, stock, subcontracting, and lot-sizing

·         Identify, negotiate, and resolve conflicts

·         Maintain planning bills

5 Comments (+add yours?)

  1. Eiji
    Sep 14, 2013 @ 02:31:05

  2. penny
    Oct 08, 2013 @ 03:53:08

  3. Shevonne
    Jun 05, 2016 @ 18:42:42

  4. Suraj
    Oct 19, 2016 @ 01:04:21

  5. mansoorbagheri
    Nov 08, 2016 @ 07:53:40

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