This curriculum spans the design and execution of integrated production planning systems, comparable in scope to a multi-phase operational improvement initiative involving demand management, master scheduling, and cross-functional supply chain alignment.
Module 1: Demand Forecasting and Capacity Alignment
- Selecting between exponential smoothing and regression-based forecasting models based on historical data stability and seasonality patterns.
- Reconciling sales team projections with statistical forecasts during S&OP meetings to avoid overcommitment or underutilization.
- Adjusting capacity buffers in high-mix, low-volume environments where product changeovers impact effective throughput.
- Implementing rolling forecasts with a 12–18 month horizon while maintaining alignment with financial planning cycles.
- Integrating customer lead time commitments into forecast models to prioritize high-service-level SKUs.
- Managing forecast error escalation protocols when variance exceeds predefined thresholds across product families.
Module 2: Master Production Scheduling (MPS) Design
- Defining planning time fences that balance schedule stability with responsiveness to urgent customer changes.
- Setting appropriate MPS level (end item vs. module) in assemble-to-order environments with configurable products.
- Handling pegging logic in ERP systems to trace component demand back to specific customer orders.
- Resolving conflicts between finite capacity constraints and infinite capacity planning assumptions in master scheduling.
- Implementing time-phased ATP (Available-to-Promise) rules to support realistic delivery date quotations.
- Managing frozen zone exceptions for engineering changes or regulatory batch requirements.
Module 3: Material Requirements Planning (MRP) Execution
- Tuning MRP lot-sizing rules (e.g., lot-for-lot, POQ, fixed order quantity) based on setup cost and inventory carrying trade-offs.
- Configuring safety stock levels at raw material, component, and finished goods levels using service level targets and lead time variability.
- Resolving MRP nervousness through time-phased order release controls and firming of planned orders.
- Managing phantom bills of material for subassemblies that are never stocked but used across multiple products.
- Handling scrap factors and yield loss in BOMs for chemical or thermal processing stages.
- Coordinating MRP regeneration frequency with supply lead time volatility and procurement review cycles.
Module 4: Capacity Planning and Finite Scheduling
- Developing rough-cut capacity plans using resource profiles for critical work centers with constrained throughput.
- Implementing finite scheduling in job shops where sequence-dependent setups impact machine utilization.
- Allocating bottleneck resources using priority rules (e.g., shortest processing time, earliest due date) during overload conditions.
- Integrating labor availability, shift patterns, and maintenance downtime into capacity models.
- Validating capacity assumptions with shop floor supervisors before releasing production orders.
- Monitoring utilization vs. efficiency metrics to distinguish between planned downtime and performance losses.
Module 5: Supply Chain Integration and Supplier Collaboration
- Establishing VMI (Vendor Managed Inventory) agreements with key suppliers for high-consumption raw materials.
- Aligning internal production cycles with supplier delivery schedules to minimize inbound logistics costs.
- Implementing EDI or API integrations for real-time exchange of forecast, order, and inventory data.
- Negotiating consignment stock arrangements for long-lead or high-value components.
- Managing dual-sourcing strategies to mitigate supply disruption risks while avoiding forecast fragmentation.
- Conducting joint business planning sessions with strategic suppliers to align capacity investments.
Module 6: Production Control and Real-Time Monitoring
- Deploying shop floor data collection systems (barcode/RFID) to track work order progress and labor reporting.
- Setting up escalation workflows for production delays exceeding predefined tolerance bands.
- Using Gantt charts and dispatch lists to communicate daily priorities to supervisors and operators.
- Managing work-in-process (WIP) limits to prevent overproduction and congestion at downstream stations.
- Integrating quality hold statuses into production scheduling to prevent release of non-conforming batches.
- Reconciling actual cycle times with standard times to update routing data and improve future scheduling accuracy.
Module 7: Continuous Improvement and Performance Management
- Defining and tracking KPIs such as on-time delivery, schedule adherence, and capacity utilization across production units.
- Conducting root cause analysis on recurring planning failures (e.g., stockouts, excess WIP) using Pareto analysis.
- Implementing S&OP maturity assessments to identify gaps in cross-functional integration and data governance.
- Optimizing planning batch sizes and reorder points using total cost of ownership models.
- Refining safety stock parameters using statistical analysis of demand and supply variability.
- Upgrading planning system logic to support multi-echelon inventory optimization in distributed networks.
Module 8: Technology Enablement and System Configuration
- Configuring MRP parameters in ERP systems (e.g., SAP, Oracle) to reflect actual lead times and lot-sizing policies.
- Validating data integrity in BOMs, routings, and inventory records before system go-live or major upgrades.
- Designing user roles and authorization profiles to enforce segregation of duties in planning transactions.
- Integrating advanced planning systems (APS) with MES and ERP for synchronized production execution.
- Testing simulation scenarios for demand surges or supply disruptions using digital twin models.
- Establishing change control procedures for master data updates to prevent unplanned schedule impacts.
