1) Introduction
Summary - master scheduling, sometimes called master production scheduling, is not only the best way for a manufacturing company to improve customer service but it will, at the same time, increase stability in manufacturing and can even reduce inventory. But good master scheduling does not evolve naturally, it is a specific way of using an MRPII or ERP planning system and has to be taught. Master scheduling is not quick or easy to learn but once learnt it will allow everyone to do a better job and lead to a higher level of satisfaction all round.
Content - this master scheduling improvement course is divided into 10 sessions. Each session starts with an audiovisual presentation (between 5 and 10 minutes long using Microsoft Internet Explorer or any other browser). Following the presentation the task force should discuss issues raised and build up a programme of change. At the end of each of the 10 sessions there is a workshop to help you practice the techniques taught. Ideally the task force should have access to an MRPII (manufacturing resource planning) or ERP (enterprise resource planning) system, preferably one on which you can set up a small training database. If you do not have access to a planning system, a spreadsheet is provided which will enable you to try out most of the ideas.
Course objectives - participants will be able to take an active role in the design and development or improvement of the master scheduling function. Commercial people will understand the important role of demand management (available to promise, forecast consumption and abnormal demand). Planners will develop a framework within which to develop their master scheduling skills.
This e-course is designed for - planners, master schedulers, customer service (or whoever accepts orders and quotes lead times) and those who forecast or who are most able to forecast sales (sales or marketing).
You can preview the course and run the first session free to allow you to evaluate the course prior to purchase.
2) Overview of the 10 sessions
Session 1
On audiovisual presentation
- Identifying current operating problems, the causes of the problems and the areas that improved master scheduling can address
- The roles and different planning systems in typical companies
- Where Sales and Operations Planning fits in
- Where master scheduling fits in
- A simple master schedule example in weeks and days
- Why you need to master schedule properly and what it achieves in practice
Session 1 tasks
- Discuss and document the company's planning processes including, if necessary, the need for a Sales and Operations Plan.
- Decide whether you can get access to your current or proposed master scheduling system (preferable) and access the spreadsheet workshop example which you will receive when you register for this session
- Workshop
- open the workshop spreadsheet master production schedule page "MPS 123"
- if you are able to access a master scheduling system, set up a database with a master schedule item part number 123, a suitable description and any other data needed by the system, identify the key features of the system in particular the way forecast is entered and the way the production schedule is entered and displayed
- enter the sales forecast and MPS at date of receipt line on the system as shown on the spreadsheet
- make sure you understand the projected available balance calculation
- set up a second database or spreadsheet with quantities and lead times that are relevant to your business
Session 2
On audiovisual presentation
- The demand supply balance
- Supply management tasks
- Time fences
- emergency
- firm / planning
- authority to change the plan
- Master schedule with firm time fence examples
Session 2 tasks
- Check firm planned order functionality on your planning system
- Check firm time fence functionality
- Workshop
Enter parts 204, 241, 224, 302 and 303 into the material master file on your system using the fixed data sheet on the supplied spreadsheet. Then carry out the following actions observing what happens immediately and after running MRP; note any action messages that the system generates -
- enter the firm time fence (at day 8), run MRP.
- enter the firm planned order for 20 in day 4, run MRP
- enter customer order for 5 in day 1, run MRP
- consume the forecast, run MRP
- change orders and forecast inside and outside the firm time fence running MRP after each change
- repeat the above observing the effect on components
- move a master schedule quantity, run MRP and see the effects on components
- make sure you understand all the calculations and that the effects are written up
(note - if you are using the spreadsheet workshop you can simulate the MRP run by going down each sheet and adding planned orders at date of receipt at the first day needed to keep the projected available balance as near to zero as possible. The planned order release must be in a multiple of the order quantity. The original order quantity has been set to 1, lot for lot, but you can change this to any other quantity that makes sense for your business.)
Session 3
On audio visual presentation
- Demand management tasks
- Sales forecasting
- Sales forecast consumption
- Updating the forecast
- when, why, who, what and how
Session 3 tasks
- Check forecast functionality of your planing system
- Check all other forecasting that is carried out in the company
- Decide how best to integrate all forecasting in a way that is helpful for everyone
- Write up a draft procedure for forecasting
- Workshop
- enter sales orders and see the effect of consuming forecast "earliest first"
- see how other ways of consuming forecast effect the calculations
- add orders without consuming forecast, run MRP and see the effect on components.
Session 4
On audiovisual presentation
- Available to promise
- definition and advantages
- The logic of demand management
- Available to promise examples
Session 4 tasks
- Check available to promise functionality on your planning system
- Workshop
- practice entering sales orders (actual demand) for product 123 and observe the effect on available to promise
- enter an order larger than the available to promise and see the effect
- understand all calculations
- write up draft order entry and available to promise procedure
Session 5
On audiovisual presentation
- Abnormal (unforecast) demand
- effect and identification
- Logic of demand management including abnormal demand
- Example
- Managing abnormal demands
Session 5 tasks
- Agree definition of abnormal demand
- Agree abnormal demand policy and procedures
- Workshop
- observe the effects of consuming forecast when sales orders are entered in the workshop
- observe the effects on components requirements of abnormal demand introduced at different periods of time
- find the point in time where unforecast orders can be accommodated without material shortages
Session 6
On audiovisual presentation
- How to survive in a world of inaccurate forecasts
- Safety stock - why?
- Safety stock choices - how to decide
Session 6 tasks
- Agree current safety stock policy
- Debate cost /benefits of shorter lead time
- Write up a draft policy for safety stock and circulate
- Workshop
- add safety stock at each level in the bill of material to see the change in ability to respond to abnormal (unforecast) demand
- evaluate the cost and benefits of each strategy
- understand the safety stock calculation
Session 7
On audiovisual presentation
- What the master schedule controls
- What type of business are you?
- Which way to master schedule
- What you might master schedule
- Dealing with the "tail"
Session 7 tasks
- Understand your current method of capacity requirements planning
- Discuss the effect on resources of changes to the master schedule
- Decide which way you will master schedule all your types of product and document along with the reasoning
- Workshop
- thoroughly examine all the methods of capacity planning available on your system
(this is very limited if you are using the spreadsheet workshop)
- check all methods of master scheduling that you might need
- try planning a resource instead of a part
- look at configuration functionality if required
Session 8
On audiovisual presentation
- The computer's tasks
- Master schedule software requirements
- Planning design issues
- How the master schedule communicates
- Ways to identify master scheduling problems
Session 8 tasks
- Check that your current or intended planning software has the functionality you need
- Decide what action to take if any software shortcomings are identified
- Check your implementation complies with the best practice design and decide any action required to make any improvements necessary
- Write up your criterion for your planning system design
- Workshop
- modify the test database as necessary to comply with your design criterion
- develop and write up a simple training exercise
- try out the training programme
Session 9
On audiovisual presentation
- Master scheduler's tasks
- Master scheduler's daily function
- typical exception / action messages
- Characteristics of a master scheduler
- Demand management tasks
Session 9 tasks
- Agree the role and reporting line for master scheduling function
- Agree master schedulers' responsibilities
- Agree role and responsibilities for demand management function
- Workshop
- run the training exercise developed in the last session with planners
- run the training exercise with demand manager and sales
- draw up a training plan for anyone else appropriate
Session 10
On audiovisual presentation
- How an overloaded master schedule develops
- How to reverse the process
- How improved master scheduling addresses overall business objectives
- Master scheduling summary
Session 10 tasks
- Complete write up of new ways of working and publish
- Ensure all relevant staff are trained in :
- forecasting
- promising orders
- abnormal demand procedures
- master scheduling
- new performance measures
- Prepare "road show" to spread the gains
- Visit the BPIC web site at http://www.bpic.co.uk
4) Guarantee
- If you do not feel the course has been worth while I will refund all fees
paid, no questions asked.
5) System requirements
- Computer running Windows 98 or later.
- Microsoft internet explorer v 5 or above
Please now select from :
Phil Robinson - www.bpic.co.uk
