MASTER PRODUCTION SCHEDULING

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MASTER PRODUCTION SCHEDULING

• The Master Production Schedule
• The Rough-cut Capacity Plan

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CORE MRP II
MANUFACTURING RESOURCE PLANNING
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AGGREGATE VERSUS DETAILED FORECASTS (Review)

• Use aggregate forecasts for planning medium-range
  overall production levels.
• High long-range forecast accuracy
• Detail not needed for planning long-range
  resource use (labor, inventory, etc.)
• Use detailed forecasts for initial detailed
  short-range Master Production Schedule (MPS)
• Detailed forecasts reasonably accurate for this
  time frame
• Need product-specific detail for MPS

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FROM THE AGGREGATE PLAN TO THE MPS

• Suppose that Export TVs, Inc. has the following
  production plan for the next six months

• If they make three models, the MPS for January
  might look like

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THE MASTER PRODUCTION SCHEDULE

• An MPS starts with a forecast and a beginning
  inventory balance

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THE MASTER PRODUCTION SCHEDULE

• Inventory is projected forward until a shortage,
  or net requirement, occurs

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THE MASTER PRODUCTION SCHEDULE

• Production is scheduled to be completed (the MPS
  is a planned finish time) to cover the shortfall

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THE MASTER PRODUCTION SCHEDULE

• A planned start time the planned order
  release is determined based on lead time (here
  it is one period)

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THE MASTER PRODUCTION SCHEDULE

• The process continues until the product is
  scheduled

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THE MASTER PRODUCTION SCHEDULE

• The other product is scheduled the same way

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THE MASTER PRODUCTION SCHEDULE

• To check the feasibility of the MPS, we need to
  check the capacity requirements

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ROUGH-CUT CAPACITY PLANNING A FIRST CHECK ON
THE MPS

• Need to see if MPS is feasible
• RCCP finds approximate capacity needs in each
  workcenter given the MPS
• Quick-and-dirty reality check
• If capacity overloads, redo MPS

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THE "ROUGH-CUT" ROUTING

• The Rough-cut" routing for a product lists
• Where it is processed
• Resources needed
• Per batch or per setup
• Per unit after workcenter is setup

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan

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THE ROUGH-CUT PLAN

• The routing is applied to the planned order
  releases to obtain the capacity plan