5 steps in production planning and scheduling
Production planning and scheduling involves a systematic approach to ensure optimal and on-time production of manufactured goods. An effective way to achieve this is to divide the production process into five distinct stages, each stage having a specific purpose.
These stages provide a structured framework for organizations to optimally plan, schedule, and control their production processes. We will discuss each stage in detail below.
1. Demand forecasting and production capacity planning
The first stage of production planning and scheduling involves demand forecasting and capacity planning. Demand forecasting involves estimating future customer demand based on historical data, market trends, and other relevant factors. This helps manufacturers determine the expected volume and demand patterns for their products. Anticipating and understanding product demand helps manufacturers make the best choices in organizing and improving operations.
Once demand has been forecasted, capacity planning comes into play. This involves assessing the organization’s actual production capacity and capabilities to determine whether it can meet the expected demand. Factors such as labor availability, equipment capacity, and machine constraints are considered in this stage. The goal is to align production capacity with anticipated demand to avoid underutilization or over-utilization of resources.
APS for accurate forecasts and planning of production capacity
By analyzing historical data, market trends, and customer demand patterns, the APS (Advanced Planning and Scheduling) system provides accurate information and forecasts regarding future demand.
This helps organizations plan their production capacity appropriately, ensuring they have the appropriate resources and capabilities to meet future demands.
Through the availability of real-time data, efficient capacity planning and demand forecasting, the APS system allows companies to make well-informed decisions, while giving them the ability to react quickly to changes, allocate resources efficiently and align their production activities with customer requirements and business objectives.
2. Material planning and purchasing
The second stage focuses on inventory control, including materials planning and sourcing. In this stage, organizations identify the raw materials, components, and resources needed for production. The quantities needed are determined based on the manufacturing schedule and demand forecast.
Effective materials planning ensures timely availability of materials while minimizing storage costs and the risk of stockouts. Establishing strong supplier relationships is essential at this stage to ensure a reliable supply chain. Organizations collaborate with suppliers to coordinate delivery schedules, negotiate prices, and maintain consistent quality standards.
Efficient materials planning and, implicitly, procurement coordination contribute to optimizing production flow and preventing interruptions in the supply chain.
APS for planning the need for raw materials and supplies
APS helps determine the need for materials and raw materials, using advanced computing algorithms to analyze demand forecasts, production capacity, lead times and inventory size. The system optimizes resource consumption, including facilitating the generation of optimal supply requirements for the company.
APS also generates feasible production plans and schedules that are designed to minimize costs, maximize profits, and meet customer expectations. Production planning software helps avoid stockouts, overproduction, waste, and delays in the supply chain.
3. Production scheduling and resource allocation
The third stage involves detailed scheduling and resource allocation. This focuses on creating a comprehensive production calendar and activity planning to ensure smooth operations.
Scheduling involves assigning tasks to different workstations or production lines, taking into account factors such as equipment availability, setup times, and dependencies between jobs. Resource allocation is another important aspect of this stage. It involves determining the optimal allocation of labor, equipment, and other resources needed to accomplish specific production tasks. The goal of efficient scheduling and resource allocation is to create an efficient schedule that eliminates unnecessary downtime, bottlenecks, and delays.
APS for efficient programming and allocation of resources
Using advanced computational algorithms and real-time data, the APS system optimizes the allocation of resources, such as machinery, labor, and materials, based on production requirements. This automation eliminates errors from manual interventions and ensures more accurate and efficient production planning and scheduling.
In addition, thanks to the multi-constraint order-based scheduling function, APS creates schedules based on existing orders and applies ordering to prioritize them. The software solution schedules based on resource availability, additional constraints, or materials needed to complete the order. The system generates schedules based on operating speed or variable resources, uses machine setup times based on resources, and allows for overlaps or dead times between operations.
4. Production control and monitoring
The fourth stage concerns the control and monitoring of production. Once production is underway, it is essential to follow the progress of the work and ensure compliance with the established schedule. Production control refers to monitoring the production process, identifying deviations or bottlenecks and taking corrective action, as appropriate. In this context, visibility into the schedule and the ability to constantly adjust the plan are crucial.
Effective production control also requires the ability to see the current load of the plan and, at the same time, to predict and adapt the production process to future changes. For example, if it is observed that a certain resource is overloaded, it is essential to be able to reschedule tasks to balance the load level, reduce downtime and improve overall efficiency.
APS for production control and monitoring
APS software is a powerful tool that helps monitor the progress of works and ensures compliance with the planned schedule. It allows the user to create and update production plans, track tasks and milestones, assign resources and roles, and generate timely reports. APS software also integrates with other systems, such as production ERP – resource management software and MES software system – for the management of manufacturing activities, to provide a comprehensive view of the status and performance of the entire project.
APS helps identify and optimally solve problems. After identifying potential equipment failures, the system allows for the implementation of changes in real time to minimize their effects, readjusting the planning based on updated data in the program. By using the APS software solution, the user can achieve greater efficiency, accuracy and transparency in managing projects of any size and complexity.
5. Factory production schedule integration
Automating the planning and scheduling process by integrating production software into the factory is an essential step in the production process. Production software allows for faster, more flexible and therefore more efficient processes, and products are manufactured at a reduced cost, without affecting the quality of the goods.
By integrating production planning and scheduling software into the factory, companies will obtain a detailed picture of the number of items that can be produced in a certain period of time, as well as the equipment and resources needed for the project to proceed optimally.
Thanks to advanced calculation algorithms, the APS program balances production capacity with demand and, moreover, contributes to the planning of the entire production activity, starting from existing operations and resources to the need for raw materials or maintenance activities.
The manufacturing software program is often used in conjunction with the MES solution, which is responsible for executing the production plans generated by the APS. The information can be automatically transmitted to the workers in the production unit using the MES solution integrated into the manufacturing software to execute the activities in the factory.
The main advantages of the APS (Advanced Planning and Scheduling) solution include:
- Effective production processes, optimizing resource allocation and improving supply chain management
- Increasing operational efficiency by improving production planning and scheduling effectiveness, by reducing preparation and execution times, as well as by optimizing resource allocation and utilization
- Real-time data availability through the APS system allows for better decision-making, optimization of production schedules, and efficient capacity planning and demand forecasting.
- Improve inventory management by increasing control and visibility, minimizing stockouts and excess inventory, and minimizing costs and losses
- Proactive identification and resolution of production bottlenecks and greater reliability in meeting customer demands
- Scalability and adaptability, allowing organizations to adapt quickly to changes, easily expand operations, and respond quickly to market dynamics and business opportunities
Optimization and planning of the production process with APS – Advanced Planning and Scheduling
Plan the entire production activity, from existing operations and resources to raw material requirements or maintenance activities
What benefits have companies using Senior Software's APS system obtained?
Several companies have successfully implemented the APS solution, provided by Senior Software, and have achieved significant benefits, including improved productivity, reduced costs, increased customer satisfaction, and streamlined operations.
APS helps us manage and plan tens of thousands of operations simultaneously, ensuring that all necessary components reach the assembly line precisely at the right time, without delays or shortages. Additionally, the advanced planning solution from Senior Software enables us to efficiently handle the variability of our work centers, which differ significantly in terms of capacities.
By implementing MES and APS, Flexibil has achieved much better management of raw materials, production capacity, which has implicitly led to increased productivity and profitability. We have real-time control over all production flows and efficient planning of each operation. Another important benefit is the fact that we can control very well the productivity of each person, the employees being paid according to the volume and quality of the products made.
“The MES solution has helped us to simplify things a lot, eliminate paper from all production processes and reduce costs. Including the sales process, preparation and sending of products to the customer, involves considerably shorter times, and the risk of quantity or batch errors has been eliminated.”