Master Production Scheduling

Master Production Schedule
•Manufacturing‘s portion of the Master Schedule. It is the
anticipated build schedule, stated in specific product
configurations.
•1) Links ‘Production Planning’ to what will be built. 2)
Calculates capacity and resources needed. 3) Drives
the materials requirements plan. 4) Drives priorities
for manufacturing.
•May be stated in terms of modules constituting the end
products (rather than the end products themselves).
•Arises from a ‘Top-down’ process.
5
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2. An Example
Master Production Schedule
8

3. About
Master Production Scheduling
(as a process)
11

MPS and Time Fences
(as applied to product A)
FROZEN
0 2 Weeks 26 Weeks
SLUSHY LIQUID
Due Date
Demand
Time Fence
Planning
Time FenceA
B C D
E
(LT=2)
(LT=8)
(LT=6) (LT=5)
(LT=16)
14

4. Developing MPS
from Aggregate Plans
– An Example
17

MPS from Disaggregation of Aggregate
plans – An Example
(Continued)
Individual Product Inventory profiles associated
with the Master Production Schedule
1 2 3 4 5 6 7 8 9 10 11 12
Product - 1 280 210 140 70 0 125 250 320 240 160 80 0
Product - 2 266 432 598 559 465 345 215 140 215 260 130 0
Product - 3 0 -50 -100 55 210 160 120 80 40 30 195 360
Total
inventory 546 642 738 684 675 630 585 540 495 450 405 360
Aggregate
Plan Capacity 546 592 638 684 675 630 585 540 495 450 405 360
Deviation 0 50 100 0 0 0 0 0 0 0 0 0
Deviation
Week
Inventory
= Total inventory-inventory from the aggregate plan
20

Product Load Profiles :
1 2 3 4 5 6
5
10
15
20
25
5
10
15
20
25
1 2 3 4 5
Product-Lot
Due Date
Product – 1
Resource - X
Product – 2,
Resource - X
Product-Lot
Due Date
Rough-cut Capacity Planning :
Calculation Of Resource Requirement Profile – An Example
(Continued)
23

The MPS Hourglass
End Items
MPS
Options
Components
26
Rule: Do
Master
Scheduling
where the
smallest
number of
product
options
exists.

The Production Planning Process
Leading To Final Assembly Schedule
Summary of typical production planning schedule, for JIT Production
Planning
Stage
Purpose Planning
Horizon
Planning
Cycle
Format Developed
From
1. Long-
range plan
Plan new products and
models
Plan facilities
Plan systems changes
3-5 yrs. 6 mths to
1 year
Indefinite Corporate
forecasts and
policies
2.Production
Plan
Plan tools and materials
Supplier planning
Total manpower
1 yr. 1 month Summari
zed by
model or
family in
monthly
buckets
Long range
plan and more
detailed
forecasts
3.Master
production
schedule
Develop data over time to
evolve into final
assembly schedule.
Make major manpower
allocations
3-6
months*
1
month*
Summary
of
expected
final
assembly
schedule
in daily
buckets
Production
plan and more
detailed
forecasts and
actual orders.
Sometimes
from finished
goods system
* There may be shorter times and horizons for mix change plans for those companies which have them.
29

Mixed Model Scheduling (under JIT)
Tennant Company
Model / Week # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Total
A 21 21 42
B 17 18 35
C 49 49 98
D 21 21
42
E 11 10 21
Total # Units Kitted per
week 21 17 49 - - 21 11 21 18 49 - - 21 10 238
EOQ-Based Master Scheduling: Assembly Line Starts / Kitting
32

1
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