Formulate initial Master Production Schedule (MPS)
3
Analyze demand forecasts
4
Validate available capacity
5
Resource level evaluation
6
Approval: Production Manager for initial MPS
7
Adjust MPS following approval
8
Release MPS to the shop floor
9
Monitor production progress
10
Record actual production data
11
Rectify any discrepancies between planned and actual production
12
Revise MPS based on discrepancies
13
Approval: Operation Manager for revised MPS
14
Update MPS in the system
15
Communicate updated MPS to relevant departments
16
Monitor inventory levels
17
Update inventory records
18
Evaluate performance of MPS
19
Produce report on MPS effectiveness
20
Approval: Director for MPS performance report
Identify production requirements
This task involves determining the specific requirements for production. Consider factors such as product quantity, quality standards, and delivery timelines. The goal is to gather all the necessary information to create an effective Master Production Schedule.
1
ISO 9001
2
Six Sigma
3
Total Quality Management
Formulate initial Master Production Schedule (MPS)
In this task, create the initial Master Production Schedule (MPS) based on the identified production requirements. The MPS will serve as a blueprint for production activities, including resource allocation and production timelines. Ensure that all necessary resources and capacities are accounted for in the MPS.
1
Determine production start date
2
Allocate necessary resources
3
Create production timeline
4
Consider any capacity constraints
5
Review MPS with relevant stakeholders
Analyze demand forecasts
This task involves analyzing demand forecasts to identify potential fluctuations in customer demand. By understanding demand patterns, you can adjust the MPS to optimize production capacity and meet customer requirements effectively.
1
Moving average
2
Exponential smoothing
3
Regression analysis
4
Market research
5
Historical sales data
Validate available capacity
In this task, validate the available capacity within the production facility. Assess the capacity of machines, labor, and other resources to determine if they can fulfill the production requirements specified in the MPS.
Resource level evaluation
Conduct a thorough evaluation of the resources required for production. This includes assessing the availability of raw materials, manufacturing equipment, and skilled workforce to ensure that the necessary resources are in place to execute the MPS.
1
Check raw material inventory
2
Assess equipment functionality
3
Review workforce availability
4
Identify any resource gaps
5
Recommend resource procurement strategies
Approval: Production Manager for initial MPS
Will be submitted for approval:
Formulate initial Master Production Schedule (MPS)
Will be submitted
Adjust MPS following approval
After receiving approval for the initial MPS, make any necessary adjustments based on feedback or changes in production requirements. Ensure that the updated MPS aligns with the approved production plan.
Release MPS to the shop floor
In this task, communicate the finalized and approved MPS to the shop floor for execution. Provide clear instructions and timelines to ensure that production activities align with the MPS.
Monitor production progress
Regularly monitor the progress of production activities to ensure they are aligned with the MPS. Identify any deviations or delays and take appropriate actions to keep production on track.
1
Track production output
2
Monitor production cycle times
3
Address bottlenecks or delays
4
Ensure adherence to timelines
5
Document any issues or obstacles
Record actual production data
This task involves recording the actual production data, including the quantity of products produced, any quality issues encountered, and the duration of production cycles. Accurate data is essential for evaluating the effectiveness of the MPS and identifying areas for improvement.
1
Product defects
2
Non-conforming materials
3
Equipment malfunctions
Rectify any discrepancies between planned and actual production
If there are any discrepancies between the planned and actual production, investigate the root causes and take corrective actions to rectify the issues. This step ensures that production aligns with the MPS and any deviations are addressed promptly.
Revise MPS based on discrepancies
Based on the identified discrepancies between planned and actual production, make revisions to the MPS to improve its accuracy and effectiveness. Incorporate lessons learned from the discrepancies to optimize future production planning.
1
Adjust production quantities
2
Update production timelines
3
Reallocate resources
4
Implement quality control measures
5
Communicate revisions to relevant stakeholders
Approval: Operation Manager for revised MPS
Will be submitted for approval:
Adjust MPS following approval
Will be submitted
Update MPS in the system
After revising the MPS, update the system or software used for tracking and managing production schedules. Ensure that all stakeholders have access to the updated MPS to maintain transparency and alignment.
Communicate updated MPS to relevant departments
In this task, inform relevant departments or teams about the updated MPS. Share the revisions made and highlight any changes that may impact their workflows or resource allocation.
Monitor inventory levels
Regularly monitor the inventory levels to ensure that they align with the production requirements specified in the MPS. Identify any shortages or excess inventory and take appropriate actions to maintain optimal inventory levels.
1
Conduct regular stock counts
2
Analyze inventory turnover rate
3
Identify slow-moving or obsolete inventory
4
Coordinate with procurement for replenishment
5
Optimize inventory storage and organization
Update inventory records
In this task, update the inventory records to reflect the actual inventory levels. Ensure that the records are accurate and up to date to facilitate effective inventory management and demand planning.
Evaluate performance of MPS
Assess the performance of the Master Production Schedule (MPS) based on key performance indicators (KPIs) such as adherence to production timelines, resource utilization, and customer satisfaction. Identify areas for improvement and develop strategies to enhance the effectiveness of the MPS.
1
Quantitative analysis
2
Qualitative feedback
3
Benchmarking
4
Surveys
5
Production data analysis
Produce report on MPS effectiveness
Create a comprehensive report on the effectiveness of the Master Production Schedule (MPS). Include an analysis of the MPS performance, any identified areas for improvement, and recommendations for optimizing the production planning process.
