INTRODUCTION FOR PRACTICAL PRODUCTION & MATERIALS PLANNING: TOOLS, TECHNIQUES, AND EXECUTION
Effective production and materials planning is the backbone of any efficient manufacturing or supply chain operation. Yet, many professionals struggle with balancing demand, managing inventory, and optimizing production schedules in dynamic environments.
This 2-day practical workshop is designed to bridge the gap between theory and real-world application. Through hands-on exercises, interactive simulations, and tool-based learning, participants will gain the skills needed to plan more accurately, respond to disruptions, and improve overall planning performance. Whether you’re new to planning or looking to sharpen your skills, this course will provide actionable tools and techniques you can implement immediately.
LEARNING OBJECTIVE
- Understand Core Planning Concepts: Gain a solid foundation in the principles of production and materials planning, including key terms like MRP, MPS, BOM, and inventory metrics.
- Apply Tools for Effective Scheduling and Forecasting: Learn to use practical tools such as Excel and planning software to create production schedules, forecast demand, and manage inventory levels.
- Analyze and Optimize Resource Utilization: Develop the ability to assess capacity constraints, identify bottlenecks, and make informed decisions to optimize production efficiency.
- Improve Accuracy and Responsiveness in Planning: Learn techniques to improve data accuracy, reduce plan-vs-actual variances, and respond quickly to changes in demand or supply.
- Solve Real-World Planning Challenges: Apply structured problem-solving methods (e.g., 5 Whys, root cause analysis) to resolve common planning issues and continuously improve processes.
LEARNING OUTCOMES
- Create and manage a Master Production Schedule (MPS): Develop a schedule based on demand forecasts, lead times, and capacity constraints using real-world data.
- Build and execute a Materials Requirements Plan (MRP): Calculate material needs using BOM structures, lot sizing techniques, and inventory policies.
- Analyze and improve inventory performance: Use tools like EOQ, ABC analysis, and safety stock calculations to balance availability with cost.
- Design efficient production schedules under constraints: Apply capacity planning and shop floor control techniques to maximize throughput and minimize delays.
- Identify and solve planning issues using structured problem-solving: Use methods like root cause analysis, PDCA, and data dashboards to troubleshoot and optimize planning processes.
LEARNING METHODOLOGY: WORKSHOP-BASED APPROACH
This course uses an interactive, hands-on workshop format designed to ensure participants not only understand key concepts but also apply them to real-world scenarios. The methodology includes:
- Short Concept Briefings: Each topic begins with a concise, practical explanation of key concepts, supported by real-life examples from manufacturing and supply chain environments.
- Interactive Exercises & Simulations: Participants will actively engage in exercises such as building MPS and MRP plans in Excel, scheduling under constraints, and balancing inventory levels.
- Case Studies & Problem Solving: Real-world planning challenges will be presented in group case studies, allowing participants to collaborate, analyze, and propose data-driven solutions.
- Tool-Based Practice: Focus on Excel-based tools and simplified ERP/MRP simulations to practice planning logic, calculations, and decision-making.
- Group Discussions & Peer Sharing: Participants will share their own planning challenges and insights, fostering peer learning and cross-industry exposure.
- Action Planning: At the end of the course, each participant will create a personalized action plan for implementing the tools and techniques learned in their own workplace.
COURSE CONTENT
Day 1: Foundations & Core Tools
🕘 09:00 – 09:30 | Welcome & Course Overview
- Introductions
- Learning objectives
- Icebreaker activity: Common challenges in planning
🕘 09:30 – 11:00 | Session 1: Understanding the Production Planning Cycle
- Overview of Production Planning vs. Materials Planning
- Levels of Planning: Strategic, Tactical, Operational
- Key terms: MPS, MRP, BOM, Lead Time, Safety Stock
- Case Study: Planning Flow in a Manufacturing Firm
- Activity: Map out your current planning process
☕ 11:00 – 11:15 | Break
🕚 11:15 – 12:45 | Session 2: Master Production Scheduling (MPS)
- Demand Forecasting Basics
- MPS creation using historical sales data
- Constraints: Capacity, Resources, Inventory
- How MPS connects with MRP
- Workshop: Create a basic MPS from sample data
🍽 12:45 – 13:30 | Lunch Break
🕐 13:30 – 15:00 | Session 3: Materials Requirement Planning (MRP)
- How MRP works: Inputs, Outputs, Logic
- BOM explosion
- Lot sizing & inventory policies
- Pegging and netting logic
- Tool Practice: Build a simple MRP in Excel
☕ 15:00 – 15:15 | Break
🕒 15:15 – 16:30 | Session 4: Inventory Management in Planning
- EOQ, ROP, Safety Stock calculation
- ABC Analysis for Material Prioritization
- Cycle Counting and Inventory Accuracy
- KPI discussion: Inventory Turns, Fill Rate, Days on Hand
- Activity: Calculate optimal stock levels for selected SKUs
🕓 16:30 – 17:00 | Q&A + Recap
- Key takeaways
- Open questions
Day 2: Planning, Problem Solving & Digital Tools
🕘 09:00 – 10:30 | Session 1: Capacity Planning & Shop Floor Control
- Types of Capacity: Finite vs. Infinite
- Load vs. Capacity Reports
- Gantt Charts, Dispatch Lists, Prioritization
- Managing Bottlenecks & Line Balancing
- Simulation: Adjust capacity to meet changing demand
☕ 10:30 – 10:45 | Break
🕥 10:45 – 12:15 | Session 2: Production Scheduling Techniques
- Scheduling strategies: Push vs. Pull, Make-to-Order vs. Make-to-Stock
- Forward vs. Backward scheduling
- Real-time adjustments: Handling delays and breakdowns
- Activity: Create a weekly production schedule using constraints
🍽 12:15 – 13:00 | Lunch Break
🕐 13:00 – 14:30 | Session 3: Using Excel & Planning Tools
- Practical Excel tools for MRP and Scheduling
- Visual Boards & Dashboards
- Data accuracy, system integration tips
- Hands-On: Build a planning dashboard in Excel
☕ 14:30 – 14:45 | Break
🕝 14:45 – 16:00 | Session 4: Problem Solving & Planning Optimization
- Root cause analysis for planning issues
- Plan vs. Actual Variance
- Continuous improvement tools: PDCA, 5 Whys, Pareto
- Cross-functional collaboration in planning
- Case Study: Solve a planning failure scenario
🕓 16:00 – 17:00 | Final Review & Action Planning
- Recap of tools and techniques
- Personal action plans: What to implement in your job
- Feedback
