Master Planning and Scheduling - An Essential Guide to Competitive Manufacturing

Discover the practical, real-world advantages of the Oliver Wight master planning and scheduling methodology.
 
The newly revised Fourth Edition of Master Planning and Scheduling: An Essential Guide to Competitive Manufacturing delivers a masterful exploration of today's master planning and scheduling techniques, as well as an insightful discussion of the future of the master planning and scheduling processes and profession.
 
Written in the context of an ever-evolving digital environment and augmented with new and critical information required to implement best practices, the book is a guide for practitioners and leaders on the principles of master planning and scheduling and its application in modern and future work environments.
 
In this book, readers will learn:
* Insights regarding top-down, bottom-up, and side-to-side integration of business practices in support of a company's strategic direction and tactical deployment
* The critical link between time-phased integrated business planning, master planning, master scheduling, capacity planning, and material planning
* "How-to" details and examples to support master planning and scheduling implementation and enhancements within the company's demand and supply organizations
 
Master Planning and Scheduling is an indispensable guide for supply chain professionals, planners and schedulers in all functional domains of a business. It also belongs on the bookshelves of any executive or manager who seeks to improve their understanding of best practice planning and scheduling processes and how those processes enable a business to outperform the competition through alignment, integration and synchronization across all functions in an organization.

List of contents

Acknowledgments xxiii
 
Foreword xxix
 
Introduction xxxi
 
Initial Thoughts xxxix
 
1 Chaos in Manufacturing 1
 
Problems in Manufacturing 2
 
And the Solutions 7
 
Getting Out of the Overloaded Master Plan and/or Master Schedule 16
 
Rescheduling the Overloaded Master Plan and/or Master Schedule 19
 
2 Why Master Planning and Scheduling 25
 
The Four Cornerstones of a Manufacturing Business 25
 
Between Strategy and Execution 27
 
What Is a Master Plan versus a Master Schedule? 31
 
Maximizing, Minimizing, and Optimizing 32
 
Objectives of Master Planning and Scheduling (If You Don't Know Where You're Going, Any Road Will Get You There) 33
 
Challenges for the Master Planner and Master Scheduler 35
 
Principles of Master Planning and Scheduling 37
 
MPS, MRPII, ERP, SCM, and ITP 39
 
Finding the Diamond in the Rough--Why It's Important 58
 
The Four Cornerstones of Manufacturing Revisited 67
 
Four Levels of Planning (Sometimes Use Only Three) 68
 
Why Master Planning and Scheduling Is a Must in Business Excellence 74
 
3 The Mechanics of Master Planning and Scheduling 79
 
The Importance of Master Planning and Scheduling 79
 
The Master Planning and Scheduling Matrices 80
 
Master Scheduling in Action 87
 
Why and How Master Scheduling Drives Material Requirements Planning and Detailed Scheduling 92
 
The What, Why, and How of Safety Stock 99
 
Additional Material Planning Techniques 103
 
Maintaining Demand/Supply Balance Inside the Planning Time Fence 107
 
Master Plan and Schedule Design Criteria 113
 
So, What's Next? 115
 
4 Managing the Supply Chain with Master Planning and Scheduling 117
 
The Master Planner's and Master Scheduler's Job 119
 
Exception-Driven Action Messages 125
 
Six (Sometimes Seven) Key Questions to Answer 129
 
Answering the Six (or Seven) Questions 133
 
Time Zones as Aids to Decision Making 134
 
Planning Within Master Planning and Scheduling Policy 138
 
No Past Dues 141
 
Managing with Planning Time Fences 142
 
Load-Leveling in Manufacturing 147
 
Lean Manufacturing and Continuous Improvement 150
 
Mixed-Model Scheduling 151
 
Planned Plant Shutdowns 154
 
5 Using the MPS Output for Make-to-Stock Products 159
 
The Master Schedule Screens 160
 
Working Make-to-Stock Master Scheduled Items 168
 
Time Phasing the Bills-of-Material 170
 
Understanding Exception-Driven Action Messages 172
 
Bridging Data and Judgment 180
 
The Seven Key Questions Revisited 184
 
Scheduling in a World of Many Schedules 185
 
From Master Planning and Scheduling to Time-Phased Material Requirements Planning 194
 
From Master Planning to Master Scheduling (It's Called Master Planning and Scheduling) 199
 
6 Where and What to Master Plan and Master Schedule 203
 
Manufacturing Strategies Defined 204
 
Choosing the Right Manufacturing Strategy 206
 
Master Planning, Master Scheduling, and Product Structures 210
 
Multilevel Master Planning and Scheduling 213
 
Ensuring That Supply Plans and Schedules Are Aligned, Synchronized, and Integrated 216
 
Master Scheduling Capacities, Activities, and Events 224
 
7 Scheduling in a Flow Environment 227
 
Different Manufacturing Environments 228
 
Similarities Between Intermittent and Flow Environments 232
 
Product Definition 236
 
The Planning Process 239
 

About the author

JOHN F. PROUD is a business advisor with Oliver Wight. Throughout his career, Mr. Proud has enjoyed collaborating with several large companies, from Lockheed Martin and Boeing to Weyerhaeuser and Starbucks. He has educated and consulted throughout the USA as well as around the free world. Numerous companies under his leadership and coaching have implemented supply chain management including master planning and scheduling best practice principles for more than 50 years. Mr. Proud was a recipient of Who's Who Albert Nelson Marquis Lifetime Achievement Award in 2021 and will be listed in Who's Who in America in 2022. ERIC DEUTSCH is a business advisor with Oliver Wight, working with companies to implement and improve their integrated business planning processes. He has an academic background and career experience in the biotech industry and, since starting his consulting practice, has worked across many industries to coach and advise clients through transformational change. In addition to advising clients, he is a member of the Oliver Wight Board of Directors, and teaches the Oliver Wight Master Planning and Scheduling Course offered publicly several times per year.

Product details

• Authors: Eric Deutsch, Jf Proud, John F Proud, John F. Proud, John F. Deutsch Proud, Proud John F.
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 31.12.2021
• EAN: 9781119809418
• ISBN: 978-1-119-80941-8
• No. of pages: 960
• Series: The Oliver Wight Companies; Oliver Wight Manufacturing
• Subjects: Social sciences, law, business > Business > Individual industrial sectors, branches; BUSINESS & ECONOMICS / Industrial Management, Business & management, Produktionssteuerung, Wirtschaft u. Management, Production Operations Management