Table of Contents
MPR CPIM aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company
Š 2014 APICS Confidential and Proprietary
Table of Contents Participant Workbook Page
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
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company Š 2014 APICS
i
Instructor Guide Version 4.3
Master Planning of Resources
Session 2窶認orecasting Demand Demand Forecasting Concepts窶ｦ .................................................................................. 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.................................................................................................
2-59
Collaborative Planning, Forecasting, and Replenishment ....................................................... 2-63
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company Instructor Guide Version 4.3
ii
ﾂｩ 2014 APICS
Table of Contents Participant Workbook Page
Session 3—Demand Management and Customer Service Evaluating Forecast Performance .................................................................................
3-7
Guidelines for Evaluating Forecasts.......................................................................................... Outcomes of Forecast Evaluation ............................................................................................. Determining Forecast Error........................................................................................................ Standard Deviation.....................................................................................................................
3-7 3-9 3-9 3-21
Customer Relationship and Order Management ..........................................................
3-25
Customer Relationship Management (CRM) ............................................................................ Customer Order Management ................................................................................................... Effective Customer and Internal Communication .................................................................... Order Delivery Performance Measurement ..............................................................................
3-25 3-33 3-39 3-41
Customer Service and Safety Stock ..............................................................................
3-49
Purpose of Safety Stock ............................................................................................................. Customer Service Levels............................................................................................................ Calculation of Safety Stock ........................................................................................................ Customer Service Policy and Performance Targets .................................................................
3-49 3-51 3-53 3-61
Š 2014 APICS
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company iii Instructor Guide Version 4.3
Master Planning of Resources
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
Instructor Guide Version 4.3
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company iv Š 2014 APICS
Table of Contents Participant Workbook Page
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 ................................................................................................... Make-to-Stock S&OP Plan.......................................................................................................... Developing a Make-to-Stock S&OP Grid ................................................................................... Financial Evaluation of Level and Chase .................................................................................. Developing a Make-to-Order S&OP Grid… ................................................................................ Resource Planning… ..................................................................................................................
5-31 5-33 5-35 5-41 5-47 5-57
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company © 2014 APICS
v
Instructor Guide Version 4.3
Master Planning of Resources
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
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company Instructor Guide Version 4.3
vi
Š 2014 APICS
Table of Contents Participant Workbook Page
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
© 2014 APICS
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company vii Instructor Guide Version 4.3
Master Planning of Resources
Session 8—Case Studies Case Studies ................................................................................................................... 8-7 Production Planning Methods .................................................................................................... 8-7 Master 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
Index Index ................................................................................................................................ Index 1
aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company Instructor Guide Version 4.3
viii
© 2014 APICS