What is the difference between production planning and scheduling?
Summary
TLDRThis script distinguishes between production planning and scheduling, highlighting their roles in manufacturing. Planning is a high-level overview that balances resources and demand over a 6-month to 3-year horizon, focusing on quantities, inventory, and investments. Scheduling, on the other hand, is more detailed, concentrating on the production of individual items or SKUs within a shorter time frame, often up to a year. It involves assigning specific tasks to workers and machines, synchronizing resources, and ensuring timely delivery to meet customer needs. Both processes are crucial for efficient production and are closely linked, with planning setting the stage for detailed scheduling.
Takeaways
- š Production planning and scheduling are closely related but distinct processes in manufacturing.
- š Production planning is a strategic, high-level process that involves balancing resources and demand over a longer time horizon (6 months to 3 years).
- š Planning requires inputs like Bill of Materials, stock availability, resource costs, lot sizes, and manufacturing lead times.
- š ļø Scheduling is more detailed and operational, focusing on the short-term (1 month to 1 year) and assigning specific tasks to resources.
- ā±ļø The time buckets for planning are weeks or months, while scheduling can be as detailed as hours or minutes.
- šØāš¼ Top management is typically involved in planning, whereas scheduling involves middle management and shop-floor execution.
- š Both planning and scheduling are iterative processes that inform and are informed by actual production outcomes.
- š The goal of scheduling is to create a detailed calendar of operations, assigning resources and workers to meet customer needs.
- š Production planning and scheduling are essential for efficient resource utilization and meeting production targets.
- š The two processes are complementary, with planning setting the stage for scheduling, which in turn enables effective production control.
Q & A
What is the primary difference between production planning and scheduling?
-Production planning involves the whole manufacturing process on a high level to produce finished goods, balancing resources and demand, while production scheduling is more detailed, defining the production quantities of single finished products or SKUs, assigning specific resources and workers, and planning detailed steps.
What resources are typically needed for both production planning and scheduling?
-The resources needed include Material, People, Machinery and equipment, Energy, and Management. Management is considered the 'software' of the company, defining how to convert raw materials into final products efficiently.
How does production planning balance resources and demand?
-Production planning balances resources and demand by determining quantities to produce per family of products, desired inventory levels, resources to use per period, and investments necessary to match capacity and volume with demand.
What is the time horizon for production planning?
-The time horizon for production planning is typically from 6 months to 3 years, involving top management and looking at planning buckets by weeks or months.
Can you provide an example to illustrate the concept of a Bill of Materials (BOM)?
-A Bill of Materials is a broken-down list of components and subcomponents needed to make the final product. For instance, in baking a cake, the BOM would include all the ingredients required, such as flour, sugar, eggs, etc.
How does production scheduling differ in terms of time horizon and detail compared to planning?
-Production scheduling has a shorter time horizon, typically between one month and one year, and a higher level of detail. It focuses on defining the production quantities of individual finished products or SKUs, assigning specific resources and workers, and planning all detailed steps.
What are the planning buckets in production scheduling?
-In production scheduling, planning buckets can be as short as hours or minutes, allowing for a more granular control over the production process and resource allocation.
Why is it important to consider the availability of items in stock when planning production?
-Considering the availability of items in stock is crucial for activating purchasing when necessary or utilizing existing stock, which helps in managing inventory levels and preventing stock-outs or excess inventory.
How does production scheduling help in bridging the gap between planning and actual production?
-Production scheduling acts as a bridge by scheduling every single operation at a specific time, assigning resources and workers, and planning detailed steps. It ensures that necessary resources are available at the right time, thus facilitating smooth production.
What is the role of management in the production planning and scheduling process?
-Management plays a pivotal role by defining how to combine the first four elements (material, people, machinery, and energy) efficiently. It is responsible for the strategic direction and execution of activities, ensuring that the production process is aligned with company goals.
How does production planning and scheduling contribute to efficient resource utilization?
-Both production planning and scheduling contribute to efficient resource utilization by ensuring that limiting resources are combined in the most effective way to produce final products. Planning determines when to make products, while scheduling focuses on how to make them happen in detail.
Outlines
š Understanding the Distinction Between Production Planning and Scheduling
This paragraph elucidates the subtle yet significant differences between production planning and scheduling. It emphasizes that while both concepts are integral to the manufacturing process, they serve distinct purposes. Production planning is depicted as a high-level overview that encompasses the entire manufacturing process, focusing on aligning resources with demand over a medium to long-term period, typically ranging from six months to three years. It involves top management and considers factors such as Bill of Materials, stock availability, cost of resources, lot sizes, and manufacturing lead times. The paragraph uses the analogy of baking a cake to illustrate these planning elements, highlighting the importance of management as the 'software' that orchestrates the conversion of raw materials into finished goods. On the other hand, production scheduling is portrayed as a more detailed and immediate step that follows planning. It concentrates on the short-term, with a time horizon that can extend from one month to one year, and involves middle management and shop-floor operations. Scheduling assigns specific tasks to machines and workers, determines inventory levels for individual products, and synchronizes resources to meet precise customer needs.
š The Sequential Process of Planning and Scheduling in Production
The second paragraph delves into the sequential nature of production planning and scheduling, using a chips manufacturing company as a case study. It underscores the necessity of both processes for effective production control and accurate scheduling. The planning phase involves forecasting sales volumes, assessing the capacity of ovens and other equipment, considering infrastructure requirements, determining the workforce and their skills, planning shifts, and setting inventory levels for raw materials and finished goods. The scheduling phase, which is the subsequent step, addresses the operational details such as which machines will operate, who will operate them, and the precise timing and quantities of ingredient requirements. The paragraph concludes by emphasizing the interdependence of planning and scheduling, and how they collectively contribute to the actual production output, which in turn provides feedback to refine these processes.
Mindmap
Keywords
š”Production Planning
š”Production Scheduling
š”Resources
š”Bill of Materials (BOM)
š”Inventory Levels
š”Lead Time
š”Capacity
š”SKUs (Stock Keeping Units)
š”Management
š”Purchasing
š”Cost of Resources
Highlights
Production planning and scheduling are similar but have distinct differences.
Production planning involves the entire manufacturing process on a high level.
Planning balances resources and demand, with a time horizon from 6 months to 3 years.
Key inputs for production planning include Bill of Materials, stock availability, and manufacturing lead time.
Production scheduling is more detailed and focuses on short-term production quantities and assignments.
Scheduling defines who or which machine will produce each SKU and has a shorter time horizon.
Production planning is the first step, followed by scheduling for detailed execution.
Management is crucial in combining the first four elements (material, people, machinery, energy) efficiently.
The planning process involves top management and considers the desired inventory levels and necessary investments.
Production scheduling requires frequent review by middle management and is closely tied to the shop-floor.
Both planning and scheduling are necessary for accurate production schedules and control.
The purpose of both planning and scheduling is to combine finite resources effectively to produce final products.
Production planning looks at when something could be made, while scheduling looks at how it will be made in detail.
An example of planning includes determining the volume of chips to sell and the necessary infrastructure.
Scheduling, in the chips company example, involves deciding which machine runs and who operates them.
Production activity provides actual volumes and results, feeding back into both planning and scheduling processes.
Transcripts
What is the difference between production planningĀ Ā
and scheduling? The difference betweenĀ production planning and production scheduling.Ā Ā
They have similar concepts, however, there areĀ slight differences between them. Planning andĀ Ā
scheduling are similar concepts. However, thereĀ are slight differences between them. The resourcesĀ Ā
needed for production planning and schedulingĀ are: Material; People; Machinery, equipment;Ā Ā
Energy; Management. The first four elements of theĀ previous list are material assets. The managementĀ Ā
is the brain that defines how to convert theĀ raw materials into final products. It is theĀ Ā
āsoftwareā of the company, in other words, theĀ way of performing activities. We can add thatĀ Ā
two companies producing similar articles canĀ have different ways of doing (or productionĀ Ā
processes). Through management, the first fourĀ elements will be combined in the most efficientĀ Ā
way to make finished goods. Production planningĀ involves the whole manufacturing process on aĀ Ā
high level in order to produce finished goods. ByĀ planning it is possible to describe the whole map,Ā Ā
which goes over all the resources to the finalĀ products. The production planning balances theĀ Ā
resources and the demand. Quantities to produceĀ per family of products; Desired inventory levels;Ā Ā
Resources to use per period; InvestmentsĀ necessary to match capacity and volume; demand.Ā Ā
The time horizon is from 6 months to 3 years andĀ involves the top management. The planning buckets,Ā Ā
the smallest unit of time that is looked at,Ā are by weeks or months. Letās see below in moreĀ Ā
detailed the required inputs for making a properĀ production plan: Bill of Materials: the brokenĀ Ā
down list of components and subcomponents thatĀ make the final product. The availability of itemsĀ Ā
in stock: Sometimes it is necessary to activateĀ purchasing; sometimes they are already on hand.Ā Ā
Cost of resources, to produce items inĀ compliance with quality needs. Lot sizesĀ Ā
involving the frequency and the proper volumeĀ to have the right quantity on hand. It preventsĀ Ā
the organization to fall down into stock-out orĀ excess of stock. The manufacturing lead time,Ā Ā
which means the time that production takes toĀ convert the raw material into finished goods. ToĀ Ā
give a simple example in the daily life, you canĀ assume you are making a cake. You will need: TheĀ Ā
ingredients you combine to make a cake (the billĀ of materials or BOM); The ingredients you alreadyĀ Ā
have at home (Stock on hand); The ingredientsĀ you need to buy (Purchasing); How much will theĀ Ā
preparation cost? (The cost of resources); HowĀ many kg of ingredients and when do you need them?Ā Ā
(The frequency and lot sizes); How long willĀ it take to produce the cake to fulfill all theĀ Ā
guests? (The lead time). The next step involvesĀ the internal combination of resources to produceĀ Ā
the final items. Following the cake example wouldĀ be the way of cooking it. Production schedulingĀ Ā
is more detailed oriented in comparison to theĀ production planning. It is also the next stepĀ Ā
going from general to detail. The time horizon isĀ shorter than the production plan and also it has aĀ Ā
higher level of detail: It defines the productionĀ quantities of single finished products or SKUs,Ā Ā
instead of product families. It defines who orĀ which machine will produce every single SKUs.Ā Ā
The time horizon is shorter and more detailed,Ā between one month and one year, depending theĀ Ā
industry and management type. The planning bucketsĀ could be as short as hours or minutes. It definesĀ Ā
the inventory level of single finished products orĀ SKUs, instead of product families. It requires aĀ Ā
higher review frequency of middle management andĀ ātouchesā more the shop-floor. After productionĀ Ā
planning, the next step is to create a detailedĀ production schedule. The goal is to schedule everyĀ Ā
single operation a certain time in the calendar,Ā assign the resources and workers, and plan allĀ Ā
the detailed steps: It is not a forecast, but itĀ needs to see the future and to get the appropriateĀ Ā
resources in time. It is a bridge betweenĀ production planning and the actual productionĀ Ā
and it helps to get the necessary resourcesĀ in a wise time manner. Identify and get theĀ Ā
appropriate amount of workers. Identify and getĀ the appropriate raw materials. Identify and assignĀ Ā
appropriate machinery and equipment. SynchronizeĀ effectively all the resources to define prioritiesĀ Ā
and reach customer needs. As you will see, in bothĀ stages it is important to consider that resourcesĀ Ā
are finite. The purpose is to combine the limitingĀ resources to get the final products in the mostĀ Ā
effective way. The planning steps look at whenĀ something could be made in general, the schedulingĀ Ā
step looks at how something will be made happenĀ in detail. Letās say your organization sells aĀ Ā
variety of chips to the market. The operationalĀ team will start preparing the production plan and,Ā Ā
at this stage, they will define: The volumeĀ of chips they expect to sell within one year.Ā
The capacity of ovens, fryers, bag makers,Ā etc. necessary to sustain the sales volumesĀ Ā
every month. The infrastructure (layout, space,Ā equipment, pallets, forklifts, tools) necessary toĀ Ā
operate without bottlenecks. The number of workersĀ and skills necessary to operate the machinery. TheĀ Ā
number of shifts available and needed during theĀ year. The desired inventory levels of flour, oil,Ā Ā
salt, additives, water, potatoes, corn, packagingĀ and other raw material at the beginning and end ofĀ Ā
every month. The expected amount of tons and unitsĀ necessary in the finished good warehouse at theĀ Ā
beginning and end of every month to sustain theĀ throughput. Following the chips company example,Ā Ā
the company will proceed to the next stage:Ā production scheduling. At this stage,Ā Ā
the following questions will be answered: WhichĀ machine will be running every shift, day and week?Ā Ā
Who is going to operate each machine every shift,Ā day and week? What is the necessary amount ofĀ Ā
ingredients, when they must arrive, when theyĀ must be ordered? It is important to remark thatĀ Ā
both are necessary: production planning andĀ production scheduling. Production planning isĀ Ā
the natural first step and production schedulingĀ goes next. Thanks to them it is possible to get anĀ Ā
accurate production schedule and suitableĀ production control. Finally, productionĀ Ā
activity will provide the actual volumes andĀ results and will feed back to both processes.
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