Implementation of Production Scheduling

The most prevalent production problems often stem from unfeasible tasks assigned to schedulers, production capacity limitations, material shortages, and conflicting order priorities. Resolving these challenges typically requires intervention at higher-level planning processes such as S&OP, MPS, and inventory management. Addressing another common issue, the excessive detail of schedules, necessitates the implementation of an efficient scheduling process to facilitate quick updates and adaptations.

We propose a three-step method, which includes:
Step 1. SCM Training. Supply Chain Management
Step 2. PSC Training. Production Scheduling & Control
Step 3. Implementation Workshops

Benefits after completing the pathway:

• Implementation of a production management system that reduces the workload on the planning department while ensuring high reliability and on-time order fulfillment.
• Development of a production management system geared towards reducing production lead time by minimizing in-process inventory while maintaining a high level of customer service.
• Selection of the optimal production management and scheduling method (CRP, DBR/S-DBR, Flow/Line).

STEP 1. SCM TRAINING (SUPPLY CHAIN MANAGEMENT)

OBJECTIVE: ACQUIRING KNOWLEDGE AND OVERCOMING RESISTANCE TO CHANGE

To implement change, it is necessary to realize and convey to others that it is possible to work simpler and more efficiently than before. During the SCM training, you and your team will be able to see:

• How integrated planning impacts the entire company's operations.
• How streamlining information flow can stabilize and organize production schedules.
• The advantages and disadvantages of master scheduling versus detailed scheduling, and in which situations each type of scheduling works better.
• How different production setups affect production efficiency.
• How accurately measured production capacities affect schedule feasibility.

As part of the training, you will also receive a checklist. This checklist will enable you to assess what changes are needed in the company to ensure that scheduling implementation makes sense and identifies the areas where implementation will yield the best results. This step is crucial as it allows you to evaluate whether scheduling is indeed the best solution for the company.
To ensure a gradual implementation of changes, it's advisable to select 2-3 individuals from your team who are enthusiastic about the implementation process. Provide them with detailed knowledge about the scheduling process through the PSC training.

STEP 2. PSC TRAINING (PRODUCTION SCHEDULING & CONTROL)

OBJECTIVE: DEVELOPING CHANGE

After completing the checklist, it's essential to provide leaders with knowledge about the scheduling process. Enroll them in PSC training.

During the PSC training, leaders will learn about the logic of CRP (Capacity Requirements Planning), which forms the foundation of modern advanced scheduling tools. They will also discover how to utilize the Theory of Constraints (ToC) for production management, along with the tools offered by Lean Manufacturing to simplify scheduling.
Additionally, as part of the training, leaders will receive an implementation manual and have access to free coaching.

To ensure effective implementation, it's crucial to test the knowledge gained in the training. Select a couple of key indices that leaders can use to adapt the process to the company's characteristics and gain practical experience in its implementation. Once the prototype is refined, proceed to step 3.

STEP 3. IMPLEMENTATION WORKSHOPS

OBJECTIVE: CONSOLIDATING THE NEW APPROACH THROUGHOUT THE COMPANY

Once the process begins to yield the expected results, you can proceed to expand the implementation to the rest of the company. With the prototype serving as a living example that the new method works and is better than the old one, convincing the rest of the employees to engage in the implementation should not be a problem. If they see that the new process will make their work easier and help achieve better results, they will naturally seek its adoption.

Organize implementation workshops based on the proven case from the previous step. It should be your case!
The knowledge that leaders will acquire during the training and the experience they will gain during prototyping will make them internal experts in the process. Thanks to them, the process will be consolidated.

Interested in seeing if this method fits your organization's needs?

Contact us