CPIM Module 3
Scheduling - answer act of creating a schedule, such as a shipping schedule, master
production schedule, maintenance schedule, or supplier schedule
master scheduling - answer process where the master schedule is generated and
reviewed and adjustment are made to the master production schedule to ensure
consistency with the production plan. the master production schedule is the primary
input to the material requirements plan. the sum of the master production schedules for
the items within the product family must equal the production plan for that family
"the sum of the master production schedules for the items within the product family must
equal the production plan for that family"
master schedule - answer a format that includes time periods, the forecast, customer
orders, projected available balance, available-to-promise
master production schedule (MPS) - answer reflects anticipated build schedule for those
items assigned to the master scheduler. planning numbers that drives material
requirements planning. represents what the company wants to produce, expressed in
specific configurations, quantities, and dates
objectives of master scheduling - answer- produce what sales and production agree
should be produced
- maintain customer service at the targeted level
- make the most efficient and effective use of resources
- keep inventories and/or backlogs at desired levels
- enable valid order promises
inputs of master scheduling - answer- units of demand management (forecasting) &
orders from DCs (distribution requirements planning (DRP))
outputs of master scheduling - answer- material requirements plan(ning)
- rough-cut capacity planning
master scheduling steps - answer1. disaggregate production plan (families) into
preliminary master schedules per item
2. aggregate master schedules for all related end items
3. perform rough-cut capacity planning
4. resolves differences and publish master production schedule
workable preliminary master schedule criteria - answer- valid schedule
- valid capacity
- valid inventory or backlog
, - valid number of changeovers
- valid batches and lots (honors batch and lot size policies)
projected available balance (PAB) - answeran inventory balance projected into the
future. running sum of on-hand inventory minus requirements plus scheduled receipts
and planned orders
ending projected available balance formula - answer=beginning PAB + scheduled MPS
receipt - demand (orders or forecast)
rough-cut capacity planning (RCCP) - answerprocess of converting MPS into
requirements for key resources (labor, machinery, warehouse space, suppliers'
capabilities, money). this comparison helps establish a feasible MPS. Three
approaches: bill of labor approach, capacity planning approach, resource profile
approach
performing rough-cut capacity planning - answer- validate critical resource availability
for MPS
- specific models rather than average unit of family
- items might still have variants, so still rough-cut
If required capacity exceeds available capacity - answer- rebalance load to periods with
available capacity
- increase capacity
- overtime
- shifting workers to other tasks
- hire part-time workers or subcontract
planning horizon - answeramount of time a plan extends into the future. cumulative lead
time plus slack time.
cumulative lead time - answerlongest planned length of time to accomplish the activity
in question. (time it takes for product to be built)
time fences and zones they create - answer- frozen zone: demand time fence
(management determined)
- slushy zone: planning time fence (longest cumulative lead time)
- liquid zone
demand time fence and frozen zone - answerall capacity and materials are committed
to specific orders. based on customer orders, not forecast. changes at this point are
disruptive and costly. senior mgmt approval usually req.
planning time fence and slushy zone - answermaster scheduler has the authority to
make changes: alter priorities, make tradeoffs. this zone determined by longest
cumulative lead time of the product
Scheduling - answer act of creating a schedule, such as a shipping schedule, master
production schedule, maintenance schedule, or supplier schedule
master scheduling - answer process where the master schedule is generated and
reviewed and adjustment are made to the master production schedule to ensure
consistency with the production plan. the master production schedule is the primary
input to the material requirements plan. the sum of the master production schedules for
the items within the product family must equal the production plan for that family
"the sum of the master production schedules for the items within the product family must
equal the production plan for that family"
master schedule - answer a format that includes time periods, the forecast, customer
orders, projected available balance, available-to-promise
master production schedule (MPS) - answer reflects anticipated build schedule for those
items assigned to the master scheduler. planning numbers that drives material
requirements planning. represents what the company wants to produce, expressed in
specific configurations, quantities, and dates
objectives of master scheduling - answer- produce what sales and production agree
should be produced
- maintain customer service at the targeted level
- make the most efficient and effective use of resources
- keep inventories and/or backlogs at desired levels
- enable valid order promises
inputs of master scheduling - answer- units of demand management (forecasting) &
orders from DCs (distribution requirements planning (DRP))
outputs of master scheduling - answer- material requirements plan(ning)
- rough-cut capacity planning
master scheduling steps - answer1. disaggregate production plan (families) into
preliminary master schedules per item
2. aggregate master schedules for all related end items
3. perform rough-cut capacity planning
4. resolves differences and publish master production schedule
workable preliminary master schedule criteria - answer- valid schedule
- valid capacity
- valid inventory or backlog
, - valid number of changeovers
- valid batches and lots (honors batch and lot size policies)
projected available balance (PAB) - answeran inventory balance projected into the
future. running sum of on-hand inventory minus requirements plus scheduled receipts
and planned orders
ending projected available balance formula - answer=beginning PAB + scheduled MPS
receipt - demand (orders or forecast)
rough-cut capacity planning (RCCP) - answerprocess of converting MPS into
requirements for key resources (labor, machinery, warehouse space, suppliers'
capabilities, money). this comparison helps establish a feasible MPS. Three
approaches: bill of labor approach, capacity planning approach, resource profile
approach
performing rough-cut capacity planning - answer- validate critical resource availability
for MPS
- specific models rather than average unit of family
- items might still have variants, so still rough-cut
If required capacity exceeds available capacity - answer- rebalance load to periods with
available capacity
- increase capacity
- overtime
- shifting workers to other tasks
- hire part-time workers or subcontract
planning horizon - answeramount of time a plan extends into the future. cumulative lead
time plus slack time.
cumulative lead time - answerlongest planned length of time to accomplish the activity
in question. (time it takes for product to be built)
time fences and zones they create - answer- frozen zone: demand time fence
(management determined)
- slushy zone: planning time fence (longest cumulative lead time)
- liquid zone
demand time fence and frozen zone - answerall capacity and materials are committed
to specific orders. based on customer orders, not forecast. changes at this point are
disruptive and costly. senior mgmt approval usually req.
planning time fence and slushy zone - answermaster scheduler has the authority to
make changes: alter priorities, make tradeoffs. this zone determined by longest
cumulative lead time of the product
