master planning of resources
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Master planning of resourcesTRANSCRIPT
Table of Contents
Instructor Guide
© 2013 APICS Confidential and Proprietary
Table of Contents
Participant Workbook Page
© 2013 APICS i Instructor Guide Version 4.2
Table of Contents Session 1—Master Planning of Resources The Manufacturing Planning and Control System.............................................. 1-9
Manufacturing and Service Industry Objectives......................................................................... 1-9 Role of Manufacturing Planning and Control.............................................................................. 1-11 Manufacturing Planning Hierarchy……………............................................................................ 1-15 Role of Planning Software in MPC.............................................................................................. 1-21 Factors Affecting MPR System Design.…………........................................................................ 1-23
Master Planning of Resources………………….................................................... 1-29 Direction Setting: Strategic and Business Planning.................................................................... 1-29 Demand Management................................................................................................................. 1-33 Sales and Operations Planning…..………………………………………………………..…………. 1-41 Master Scheduling………………………...................................................................................... 1-45 Distribution Planning……............................................................................................................ 1-47
Master Planning of Resources
Instructor Guide Version 4.2 ii © 2013 APICS
Session 2—Forecasting Demand Demand Forecasting Concepts…........................................................................ 2-7
Forecasting Framework……………………….............................................................................. 2-7 Managing the Forecast…..…………............................................................................................ 2-17
Forecasting Techniques........................................................................................ 2-29 Factors Affecting the Forecast.……............................................................................................ 2-29 Qualitative Forecasting Techniques............................................................................................ 2-39 Quantitative Intrinsic Techniques................................................................................................ 2-45
Quantitative Causal Techniques................................................................................................. 2-59Collaborative Planning, Forecasting, and Replenishment........................................................... 2-63
Table of Contents
Participant Workbook Page
© 2013 APICS iii Instructor Guide Version 4.2
Session 3—Demand Management and Customer Service Evaluating Forecast Performance….................................................................... 3-7
Guidelines for Evaluating Forecasts.......................................................................................... 3-7 Outcomes of Forecast Evaluation….......................................................................................... 3-9 Determining Forecast Error……................................................................................................ 3-9 Standard Deviation……….……................................................................................................. 3-21
Customer Relationship and Order Management................................................ 3-25 Customer Relationship Management (CRM)............................................................................. 3-25 Customer Order Management..................................................................................................... 3-33 Effective Customer and Internal Communication………………………………………………….. 3-39 Order Delivery Performance Measurement............................................................................... 3-41
Customer Service and Safety Stock……….......................................................... 3-49 Purpose of Safety Stock…......................................................................................................... 3-49 Customer Service Levels……………………………………………………………………………… 3-51 Calculation of Safety Stock……………………………………………………………………………. 3-53 Customer Service Policy and Performance Targets………………………………………….……. 3-61
Master Planning of Resources
Instructor Guide Version 4.2 iv © 2013 APICS
Session 4—Distribution Planning Distribution Network Planning……….………...................................................... 4-7
Distribution Channel Design Considerations............................................................................. 4-7 Network Configuration………………………………………………..…......................................... 4-17 Transportation and Distribution Center Site Decisions……………………………………………. 4-29
Distribution Replenishment Planning……………............................................... 4-37 Product Forecasting………………………………….................................................................... 4-37 Replenishment Planning Approaches……………...................................................................... 4-43 Replenishment Planning Linkages to S&OP and Master Scheduling…................................... 4-61
Measuring Performance………………................................................................. 4-69 Distribution System Performance Measures….......................................................................... 4-71
Table of Contents
Participant Workbook Page
© 2013 APICS v Instructor Guide Version 4.2
Session 5—Sales and Operations Planning S&OP Introduction…………............................................................................... 5-7
Major Attributes.…………………………………....................................................................... 5-7 S&OP Relationships….……………………………….…………………...................................... 5-9 S&OP Fundamentals……….................................................................................................... 5-11
Management Considerations.…........................................................................ 5-13 Guiding the Business………………………………................................................................... 5-13 Roles and Responsibilities………………………………………………………………………..... 5-19 Key Planning Factors……………………………………………………………………………….. 5-21
The S&OP Process……………………….…….................................................... 5-25 S&OP Process Outcomes…………………............................................................................. 5-25 Monthly Executive S&OP Process Steps…..…………………………………………………….. 5-27
Developing and Validating the Production Plan.............................................. 5-31 Production Planning Methods……………....…………………………………………………….. 5-31 Make-to-Stock S&OP Plan…..…………………………………………………………………….. 5-33 Developing a Make-to-Stock S&OP Grid…………………………………………………………. 5-35 Financial Evaluation of Level and Chase………………………………………………...………. 5-41 Developing a Make-to-Order S&OP Grid……………………………...…………………………. 5-47 Resource Planning………………………………………………………………………………….. 5-57
Master Planning of Resources
Instructor Guide Version 4.2 vi © 2013 APICS
Session 6—S&OP and Master Scheduling Introduction…..…………..................................................................................... 6-7
Transition from Sales and Operations Planning…..…………………………………………..…. 6-7 Master Scheduling Objectives………….................................................................................. 6-7 Role in Manufacturing Planning and Control…………………………………………………….. 6-9 Maintaining the Master Schedule…………………………………………………………………. 6-11
Major Influences on Master Scheduling…………............................................ 6-13 Business Environment…..…………......................................................................................... 6-13
Master Scheduling Process.…………............................................................... 6-19 Introduction…………………………………………................................................................... 6-19 Maintaining the Stability of MPS…......................................................................................... 6-39
Table of Contents
Participant Workbook Page
© 2013 APICS vii Instructor Guide Version 4.2
Session 7—Managing the Master Schedule Management Considerations………………....…………………………………… 7-7
The Balancing Act…………………..…………………………………………….…………………. 7-7 The Role of the Master Scheduler….……………………………………………………………… 7-9 The Role of the Senior Executive………………………………………………………………….. 7-11 Planning and Coordinating Changes……………………………………………………………… 7-13 Maintaining the Integrity of the Master Schedule………………………………………………… 7-27
Assemble-to-Order Master Scheduling……..................................................... 7-31 Bills of Material........................................................................................................................ 7-31 Planning Bills of Material………..………………………………………………………………….. 7-33 Two-Level Master Scheduling Demonstration and Problems………………………….………. 7-43
Reviewing Capacity Requirements................................................................... 7-55 Rough-Cut Capacity planning................................................................................................. 7-55 RCCP Process……................................................................................................................. 7-57 Possible Solutions……..…...................................................................................................... 7-63 Overload and Underload…...................................................................................................... 7-65 Revised MPS and RCCP Report…………………………………………………………………... 7-67
Advanced Planning and Scheduling (APS)...................................................... 7-69 Approach to Capacity Planning............................................................................................... 7-69 APS Process........................................................................................................................... 7-71
Measuring Master Scheduling Performance.................................................... 7-73 Policies and Methods.............................................................................................................. 7-73 Problem Indicators.................................................................................................................. 7-75 Performance Measures…………………………………………………………………………….. 7-77
Master Planning of Resources
Instructor Guide Version 4.2 viii © 2013 APICS
Session 8—Case Studies Case Studies....................................................................................................... 8-7
Production Planning Methods………..…………………………………………….………………. 8-7Master Scheduling in a Make-to-Order Environment……………………………………………. 8-13 Master Scheduling in a Make-to-Stock Environment……………………………………………. 8-19
Appendix Progress Check Answer Sheet......................................................................... A-1 Bibliography…………......................................................................................... A-2 Course Evaluation.............................................................................................. A-3
Index Index.................................................................................................................... Index 1