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Praise for Master Planning and Scheduling— the Book, the Process, the Results! Past and Present
Be at your best when your best is needed!
“The overarching driver for supply planning and supply scheduling is the master planning and scheduling set of processes. This is covered in depth in the best book ever written on the subject, Master Scheduling (Proud 2013). Suffice to say that the term master says it all—it is the master of all other detailed supply plans and schedules. Master Planning and Scheduling is the fourth edition of the very successful Master Scheduling book (originally released in 1994).”
Rod Hozack, Stuart Harman, Todd Ferguson, and Dawn Howarth, authors of Integrated Tactical Planning, Oliver Wight International, Inc.
“In Master Planning and Scheduling, authors Proud and Deutsch bring us both the science and the art of integrated planning and day-to-day execution—application based on sound theory—written in a clear and straightforward way. The vital role of master planning and scheduling in a holistic, effective, and efficient planning and execution environment is brought to life in a real-world and compelling fashion. This book is a comprehensive resource for the education, design, implementation, and measurement of best-practice supply chain processes to support sustainable value creation and enduring competitive advantage.”
Bob Hirschey, president, Oliver Wight Americas, Inc. and former vice president, strategic planning, cellulose fibers, Weyerhaeuser Company
“Planning together, as one team . . . a novel concept that is too frequently overlooked. The work here by Proud and Deutsch reinforces the fact that planning together is imperative to the success of any organization embarking on a journey of becoming Best in Class. While executing or implementing this plan may be daunting, Master Planning and Scheduling provides a roadmap to linking the day-to-day operations with the strategic vision of the company.”
Kris Morgan, director of Planning & Third Party Manufacturing, Curation Foods, Inc.
“Proud’s third edition of Master Scheduling has been on my desk for the past 15 years. The front and back covers are missing, and the binding barely holds the pages any longer. I’ve referenced this book at least monthly irrespective of the company/ industry I was working for (consumer products, electronics, capital equipment, pharmaceutics, biotech). In each experience we reaped the rewards a great master planning and scheduling process delivers, and each MPS improvement had its origin in John’s (and now Eric’s and John’s) book.”
Paul McGuire, former planning manager, materials manager, supply chain director
“ Master Planning and Scheduling: An Essential Guide to Competitive Manufacturing is a comprehensive road map to managing a business in this competitive world. Proud (and Deutsch) teach the value of a disciplined approach to balancing supply and demand, while reducing manufacturing cost via transparency and timely diagnostics.”
Shaker Chandrasekaran, former vice president, Cellulose Fibers Manufacturing, Weyerhaeuser Company
“This latest edition of Master Planning and Scheduling further refines the definitive body of knowledge on the topic. A valid master (planning and) scheduling process has been and remains one of the most effective tools to manage the complexities of a manufacturing business and will provide the practitioner as well as the executive with valid insight and support to direct the critical activities of their enterprise.”
Michael L. Bales, former president, Delta/Unibus Corporation
“Proud (and Deutsch) clearly outline, define, and explain the process of master (planning and) scheduling. The book is an excellent read for both the beginner and practitioner, giving either one an understanding of how to apply the concepts and tools for the best results in any manufacturing environment.”
Jimmie White, materials and logistics manager, RGM Products
“Proud (and Deutsch) help the reader understand the application of master planning and scheduling principles and describe what works in great detail. Master (Planning and) Scheduling will become the text for any course on master (planning and) scheduling and the standard resource for all manufacturing companies.”
Richard C. Ling, president, Richard C. Ling, Inc.
“Master planning and scheduling, the complex integration of all management planning activities, is presented in Proud (and Deutsch’s) effective style. A tremendously broad undertaking, Master (Planning and) Scheduling is sensitive to the need of the practitioner to know how and the executive to know why.”
Richard Pugliese, former executive, Monitor Labs, Systech, and Xerox
Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data is Available:
This book was originally (and still is today) dedicated to manufacturing professionals worldwide, especially those who chose or have chosen master planning and scheduling as a career for the past 50 years and beyond.
John and Eric, 2021
Oliver Wight Principals
Additionally, this enhanced and updated master planning and scheduling book is dedicated to my late wife Darlene, who I lost in the final month of 2014. She was always the wind beneath my wings. I only regret that I did not recognize enough her contributions to my life, career, and this book during her living years!
John F. Proud, 2021
Oliver Wight Principal
Additionally, this book is dedicated to my amazing wife Claudia, my partner in life’s adventures. She keeps my inner curmudgeon in check and makes me laugh when I need it most. You’re the best, Babe. I love you!
Eric Deutsch, 2021
Oliver Wight Principal
Oliver Wight Supply Chain Management Book Series
Master Planning and Scheduling: An Essential Guide to Competitive Manufacturing, Fourth Edition
John F. Proud and Eric Deutsch
Supercharged Supply Chain: Discover Unparalleled Business Planning and Execution Practices
James G. Correll, Lloyd C. Snowden, and James Bentzley
Integrated Tactical Planning
Rod Hozack, Todd Ferguson, Stuart Harman, and Dawn Howarth
The Oliver Wight Class A Standard for Business Excellence, Seventh Edition
Oliver Wight International
The Oliver Wight Proven Path, Second Edition
Oliver Wight International
An Executive’s Guide to Achieving Class A Business Excellence
Dennis Groves, Kevin Herbert, and Jim Correll
Achieving Class A Business Excellence: An Executive’s Perspective
Dennis Groves, Kevin Herbert, and Jim Correll
Demand Management Best Practices: Process, Principles, and Collaboration
Colleen Crum with George E. Palmatier
Supply Chain Colloration: How to Implement CPFR and Other Best Collaborative Practices
Ronald K. Ireland with Colleen Crum
The Transition from Sales and Operations Planning to Integrated Business Planning
George E. Palmatier with Colleen Crum
Enterprise Sales and Operations Planning: Synchronizing Demand, Supply and Resources for Peak Performance
George E. Palmatier with Colleen Crum
The Marketing Edge: The New Leadership Role of Sales & Marketing in Manufacturing
George E. Palmatier and Joseph S. Shull
Gaining Control: Managing Capacity and Priorities, Third Edition
James G. Correll and Kevin Herbert
Purchasing in the 21st Century: A Guide to State-of-the-Art Techniques and Strategies, Second Edition
John E. Schorr
High Performance Purchasing
John E. Schorr and Thomas F. Wallace
Manufacturing Data Structures
Jerry Clement, Andy Coldrick, and John Sari
Distribution Resource Planning
Andre J. Martin
Inventory Record Accuracy, Second Edition
Roger Brooks and Larry Wilson
Orchestrating Success
Richard C. Ling and Walter E. Goddard
World Class Production and Inventory Management, Second Edition
Darryl V. Landvater
Just-in-Time: Surviving by Breaking Tradition
Walter E. Goddard
Just-in-Time: Making It Happen
William A. Sandras, Jr.
The Executive’s Guide to MRP II
Oliver Wight
Master Scheduling: A Practical Guide to Competitive Manufacturing, First through Third Editions
John F. Proud
Appendix D Master Planning and Scheduling 831
Appendix E Supply Chain Management Overall Process Flow Diagram (An Example) 843
Appendix F Master Planning and Scheduling Process Flow Diagram Examples 845
Appendix G Master Planning and Scheduling RACI Examples 851
Appendix H Master Planning and Scheduling Spinoff Task Team Charter 855
Appendix I Master Planning and Scheduling Oliver Wight International Offerings Founders’ and Co-Authors’ Biographies 859
Glossary 865
Index 895
Acknowledgments
You’re never too old to set another goal or to dream a new dream!
We are jointly grateful to a number of people who have shaped as well as enhanced our professional careers through education, coaching, and idea sharing. Many of these people are current and past members of Oliver Wight International, of which we have been members for 33 years (John) and 10 years (Eric). One person in particular, George Palmatier, has had more influence in our combined careers than the many others. George Palmatier, former Oliver Wight associate, was not only a great thought leader but a great simplifier, a quality that Oliver Wight (the man) held with high esteem. George was the man who could stand up in a room full of passionate (and opinionated) Oliver Wight principals, engage in a heated debate on one topic or another, and speak simple truths and principles that would cut right to the heart of the matter. Simply put, when George stood up, we listened. He brought the same gravitas and unique perspective to his clients. We have had the pleasure in our careers, both as clients of Oliver Wight while in industry and as Oliver Wight principals, to listen to and absorb George’s wisdom. We will be forever grateful for his influence, guidance, and friendship.
Additionally, we would like to thank our book reviewers, who spent many hours working their way through parts of this book (the entire book might have been too much for each reviewer in the time allotted in our master plan and schedule!). Those book reviewers are David Goddard, Oliver Wight Americas (OWA); Paul McGuire, OWA; Kris Morgan, Curation Foods, Inc.; Pam Lindsey, OWA; and Ben Sellers, OWA. The book’s original
xxiv Acknowledgments
reviewers should not be forgotten. Those reviewers were Darryl Landvater, OWA and the late Mike Bales, Dick Pugliese, John Sari, and Larry Wilson.
John F. Proud’s Personal Acknowledgments
I continue to find myself in a place surrounded by people who care about doing things right and doing the right things. My career has covered 50-plus years from being a naval officer to a co-author of this master planning and scheduling book. Without the navy in my background, I’m not sure what type of person I might have turned out to be. Without Oliver Wight in my past and present, I again don’t have any idea where I might have wound up. However, I do know one thing: this book and its preceding three editions might never have been written, or, if they were, I would not be one of the co-authors.
Besides the people already mentioned in my present and past acknowledgments, I want to highlight what a pleasure it was to work with Walt Goddard, Tom Gillen, Al Stevens, Dick Ling, Roger Brooks, Jim Correll, Jerry Clement, Marv Jensen, Bill Pendleton, Tom Allen, Eric Deutsch, and so many others. When I was in learning mode, they taught me. When I was in listening mode, they talked to me. When I was in teaching mode, they listened to me. When I was in troubled mode, they comforted me. And the story goes on!
Now in 2021, I once again find myself in a very privileged situation. Working for the past couple of years with my colleague, Eric Deutsch, we are proud to release this first and only definitive book covering the complete subject of master planning and scheduling.
Original Acknowledgments for Master Scheduling—A
Practical Guide to Competitive Manufacturing, First (1994), Second (1999), and Third (2007)
Editions
I am deeply grateful to a number of people who have shaped as well as enhanced my professional career through education and idea sharing. Many of these people are current and past members of the Association for Operations Management (APICS), which I have been a member of for over 25 years. However, two people have had more influence in that career than the many others.
Dick Ling, former Oliver Wight associate and former president of Arista Education and Consulting, exposed me to the real profession of master scheduling. Had I not crossed paths with Dick Ling and several other Oliver Wight associates, I would not have been able to write this book. I learned my master scheduling skills from the best in the industry— Dick Ling, Oliver Wight associates, and professional master schedulers working in Class A companies worldwide.
Dick Pugliese, while serving as general manager of a Xerox plant, gave me the opportunity to be part of a Class A Manufacturing Resource Planning system implementation. It was during this time that I learned how a manufacturing company should work if it is to be successful and achieve Class A results.
Other colleagues and associates have also taught me much about this complex subject. John Dougherty literally spent hours with me discussing and developing concepts that we hope furthered the industry’s understanding of how important master scheduling is to the manufacturing environment. Walt Goddard, John Sari, and Al Stevens also developed numerous master scheduling concepts over the years and were kind enough to share them with me. Oliver Wight associates Tom Gillen, who helped me with the engineering issues, and George Palmatier, who made sure I did justice to the demand side of the business, also deserve recognition.
Several other people who I would like to thank and acknowledge are: Dick Luecke, who was instrumental in taking my thoughts and structuring them into sentences and phrases that actually make sense; Lori Stacey, who spent hours upon hours typing, correcting, retyping, and recorrecting the lengthy manuscript; the Oliver Wight Publications staff, who have been effective, cooperative, patient, and understanding throughout this book’s entire process; and the John Wiley & Sons staff, who added the professional flavor.
Once the manuscript draft was available, Mike Bales, former vice-president operations, G & W Electric; Dick Pugliese, retired executive; John Sari, Oliver Wight Alliance; and Larry Wilson, Oliver Wight Americas principal worked their way through the many pages, challenging my thoughts and recommending changes as appropriate. Without their critical input, this book would be less than the book it is today. My “severest and best critic” was former Oliver Wight associate Darryl Landvater, who challenged not only content but organization. A special thank you goes to Darryl for his effort, time, and patience.
Another special thank you goes to my original editor and publisher, Jim Childs, as well as my current editor, Matt Holt, who I am sure I caused great grief when I missed several milestones along the way—What? The person who wrote the book on valid master schedules was “past due”? If you ever doubt how important it is for a manufacturing company to create valid schedules and then perform to these schedules in order to satisfy its customers, just give my publisher a call. In addition to Jim Childs, Dana Scannell was the first to give me the chance to write this book and encouraged me to keep going when my frustrations were high and my stamina was low.
My final thank you goes to my lovely (late) wife, Darlene, who gave me the time necessary and seldom complained about being left alone while I worked in the office. Darlene was truly my best friend, and without her understanding and encouragement, I would never have found myself in a position to write these acknowledgments for what I still believe was the first and only definitive book covering the subject of master scheduling.
Acknowledgments
Eric Deutsch Personal Acknowledgments
I am deeply grateful for those who had faith in me and enabled me to grow and learn throughout my career. Their companionship, coaching, and inspiration was, and is, invaluable to me.
I began my career at Novagen, Inc., a growing biotech company in Madison, Wisconsin. Tom Foti hired me as a dish scrubber and lab assistant while I was working to attain my Bachelor of Science degree in Bacteriology from the University of Wisconsin–Madison. When I graduated, he hired me as a laboratory production scientist, but soon I took on other supervisory and operational responsibilities outside of the lab under his guidance. Tom and I worked on many projects (scientific, operational, software implementations, etc.) and had many adventures over the ensuing years. It was then that I learned, largely through the school of hard knocks and a little scientific problem solving, how to plan and schedule for manufacturing in a growing company. I owe Tom a huge debt of gratitude.
Tim Moser seemed to appear at just the right time in my career. Tim was an intern at Novagen via the University of Madison School of Business and was hired full time after attaining his MBA in Supply Chain Management. Tim opened my eyes to the true profession of supply chain management. It was through Tim and his network of supply chain professionals that I took my “subsistence understanding” of manufacturing management to a true appreciation of the science behind operations and supply chain management. I must also thank Pete Lukszys for bringing Tim into the Novagen organization and providing his own guidance and leadership to me over the years.
Novagen was the target of several acquisitions over time, ultimately by Merck KGaA. There are many people I would like to thank: Bob Mierendorf and Lisa Johnson for showing executive leadership with heart, compassion, and integrity; Tom Van Oosbree for his leadership, scientific guidance, and being such an all-around great human being; Aditya Sobti (now an Oliver Wight principal) for his faith and guidance through lots of changes and trying times. And all of the friends and colleagues that put up with my mistakes, grew with me, and provided companionship along the way.
I had the privilege of leading the IBP/S&OP implementation in the North American divisions of Merck KGaA and we partnered with Oliver Wight in that endeavor. As a client of Oliver Wight and since joining Oliver Wight Americas, several Oliver Wight principals have been enormously generous in their guidance, mentorship, and friendship. In addition to George Palmatier, who was acknowledged earlier, Donald McNaughton and David Goddard provided valuable guidance and friendship during the Merck IBP/S&OP implementation as our coaches and as my colleagues through the present day—class A guys all the way. I thank Coco Crum for her leadership, guidance, and friendship and
for teaching me the principles of demand management. It is a great honor to be working alongside all of my Oliver Wight colleagues and to continue to learn from each of them.
John Proud, my generous and patient colleague and co-author for this fourth edition, has given me an immeasurable gift. His generosity in sharing his decades of experience and knowledge with me, both as a client and an Oliver Wight principal, is beyond compare. The faith and generosity that he has shown to include me in the writing of this fourth edition is also beyond compare. I am deeply humbled and grateful for this opportunity.
Finally, to my wife Claudia, for her love, support, and patience while I was writing the fourth edition of this book. I’m a lucky man!
