Requirements - Master Production Schedule (MPS)

MASTER PRODUCTION SCHEDULING / Rough Cut Capacity Planning

Overview

The Master Production Schedule (MPS) is a statement of the anticipated manufacturing schedule for selected items by quantity per planning period. The items on the MPS plus those on the Final Assembly Schedule (FAS) should encompass all known requirements. The MPS is a manufacturing plan of specific items by quantity, usually per week. It also is used by marketing and manufacturing to agree on how the specific demand requirements can be met with the available resources.

Forecasting and Master Production Scheduling are frequently combined as one application due to the role which the sales forecast plays in deriving the master schedule.

Master Production Scheduling (MPS)

Planning horizon

• Fixed time periods (weeks, months, quarters)
• Variable time periods (user defined)
• Unlimited periods

Planning BOM

• Multi-level (no restriction)
• Multi-level (restricted levels)
• Single level (level to end item)
• No planning BOM (end item only)

Time Fences

• Multiple time fences
• Use time fences to report plan exceptions
• Use time fences to create an unbalanced MPS
• Cover the time fence of the longest lead time of any component

Forecast Options

• Greater of forecast or demand
• Greater of forecast or demand variable by the time fence
• Non-master scheduled item demand
• Forecast only
• Demand only (actual sales)

Product environments

• Make to stock
• Make to order
• Assemble to order
• Combination
• User defined

MPS calculation

• Net change
• Regeneration
• Net change between schedules
• Available-to-promise quantity on uncommitted on-hand inventory or schedule quantity

Capacity

• Resource capacity load profile for each item
• Calculate rough cut capacity plan

Manual Input

• Pegging through the planning bill levels to demand
• Mass changes (e.g., move down all, increase 10%)

Planning types

• Support dependant and independant demand
• Support planning BOMs

Schedules

• Define daily build schedule quantities one week requirements are set
• Revise schedule on request
• Notify scheduler to verify and “firm-up” planned orders before they are generated and released to production
• Simulate changes affecting current master schedule
• Simulate custom order input that competes for capacity and resources without changing existing schedule
• Simulate master schedule or forecast changes

Forecast Consumption

• Push forecast into next bucket if not consumed in current period (snow plow)
• Drop off forecast in not sold as current period passes

Production and Rough Cut Capacity Planning

Production Planning Levels

• Part number
• Dollar (currency)
• Part family

Resource constraints by level

• Direct labor hours
• Test labor hours
• Engineering labor hours
• Production capacity in machine or work center hours
• Vendor capacity, in units or dollars
• Sales dollars
• Cost of sales dollars
• Profitability dollars
• Units
• Hours
• Dollars
• User defined (please indicate)

MPS Inquiry

• Schedule by planner
• Schedule by division
• Schedule by plant
• Schedule in unit
• Schedule in dollars
• Pegged to forecast
• Planned consumption schedule
• Net demand remaining

Rough Cut Capacity Planning Inquiry

• Pegged Load - same as report except on-line
• Where Used - same as report except on-line
• Exception - same as report except on-line

MPS Reports

• Available-to-Promise – This report presents the available-to-promise for each MPS line item. The report is timephased, usually into weekly or monthly "buckets," and provides the necessary data elements to review the logic of the planning for any one MPS line item. Typical data elements include product group and item ID, lead times and other inventory parameters, and quantity data including the forecast, MPS, onhand, onorder, committed, and availabletopromise.
• Demand Tracking Report - Provides historical data on actual shipments, and order bookings as compared to management forecasts.
• Demand Tracking Summary - Summary statistics can be made available at the end of each item number listing.
• Forecast Data Report - Summary of historical demand activity, indicates significance of errors between forecast and actual, and provides a statistical summary. The data report can identify forecast parameters that may need manual adjustment. Data included is model type, smoothing constant, trend constant, mean absolute deviation, sum of forecast errors, dynamic adjustment tracking, future month forecast factor, past actual demands.
• Management Forecast - Generated as a summary by product line and product group to present a 12 month demand with yearly totals by product group and by period for the product line.
• Period Summary Forecast - Forecast by line item within product group for each period through the future 12 periods with summaries by period for the group and yearly for line items.
• Marketing Management Summary - Forecast worksheet for revisions after the following data is presented and reviewed:
• product group forecast for 12 periods
• historical actual for the same periods in the previous year.
• management forecast as a basis of comparison
• Product Forecast Summary - Limited to a one line summary of key historical and forecast information contained in the master file. Data elements can included demand YTD, demand last YTD, last three periods, next three periods, expected yearly demand, expected demand the following twelve periods.
• Forecast Audit Summary - Automatically reports the forecast accuracy by summing the items within each error range and reporting them at a percent of the total items on a quarterly basis. This report provides an overall picture of general accuracy of forecast and the degree of significance in the errors.
• Forecast Audit Detail - Automatically generates the above information on each line item.
• Forecast Simulation Reports - Can be valuable when analyzing product group forecasts. The principal output is the value of smoothing constants and historical trend data in order to select the optimum set of smoothing constants.
• Item Demand and Forecast - Presents several years of historical data (user specified) and the next 12 months of forecast demand for each item. Typical data elements can include YTD totals, total yearly demand, and quarterly totals with comparisons by percent between items and their total product group.
• Master Production Schedule Time Series - Presents the recommended (system planned) production schedules for each line item and it's subassemblies. The report is time phased, usually into weekly or monthly "buckets", and provides the necessary data elements to review and logic of the planning for any one line-item. Typical data elements include product groups and items ID, a preset number of production periods, lead times and other inventory parameters, and quantity data including the forecast, on-hand, on-order, required, and available.
• Master Production Schedule - Exceptions - Provides the planner with over/under capacity information, negative quantities, past-due orders, missing data flags, etc.
• Master Production Schedule Transaction Errors - Daily listing of input and releases transactions which violate policy or are in error as determined by the item master file.
• Sales Orders By Ship Date - Automatically allocates sales order requirements by ship date, offset for lead time.
• Build Schedule Report - Reports the build schedule for one or all assemblies.
• Schedule versus Actual Output - Reports the actual output compared with the scheduled output at a work center.

Rough Cut Capacity Planning Reports

• Schedule - From demand loaded by the user. Hours/dollars load placed on production generated report can be segregated by planner, division, or plant.
• Pegged Load - Report of where capacity constraints are tied back to what is driving the requirement. Can be pegged to type of demand or forecast.
• Exception Report - A report of all overload and underload conditions by work center and/or machine.
• Where Used Report - Lists all parts/tools that go across each work center/machine.

MPS Interfaces

• Bill of Material Management (Item Master File) - Receives item number input/output and key the item number to product category and lead times.
• Bill of Material Management (Engineering Change File) - Receives the latest revisions are incorporated into the schedule.
• Sales Order Processing/Billing (Customer Master File) - Recieves customers order and posts available-to-promise
• Shop Scheduling/Reporting (Final Assembly Schedule) - Receives the final assembly configurations
• Capacity Requirements Planning - Posts order shcedules for confirming and scheduling capacity
• Rough Cut Capacity Planning - Posts order shedules to determine the effect upon critical resources.
• Forecasting - Receives independent demand data
• Material Requirements Planning - Translates scheduled orders into time-phased component/raw material demands.

Rough Cut Capacity Planning Interfaces

• Master Production Schedule - Provides a valid schedule of end items to be produced by the period
• Routings Management - Uses routing file as basis for calculating load