What is more Important in Production; Planning or Scheduling ?

 

Production planning and scheduling are both essential components of the manufacturing process, but they serve different purposes and focus on different aspects. Let's contrast them based on their objectives, scope, time frame, and level of detail, along with relevant examples.

 

Objective

Production Planning: The main objective of production planning is to determine what, how much, and when to produce to meet customer demand while optimizing resources. It involves analyzing forecasts, sales orders, inventory levels, and capacity to develop a feasible production plan.

Example: A car manufacturer analyzes market demand, available raw materials, and production capacity to create a monthly production plan, deciding how many cars of each model to produce.

 

Scheduling: The primary objective of scheduling is to determine the specific sequence and timing of operations or tasks required to execute the production plan efficiently. It involves allocating resources, such as labor, machines, and materials, to complete tasks in a timely manner.

Example: In the car manufacturing context, scheduling involves determining the order in which specific tasks should be performed, such as assembling engines, installing body panels, and painting.

 

Scope

Production Planning: It focuses on the broader perspective and long-term horizon. It considers factors like product mix, capacity utilization, inventory management, and overall production strategy.

Example: A bakery plans its production for the next six months, considering seasonal demand fluctuations, ingredient availability, and workforce requirements.

 

Scheduling: It zooms in on the specific tasks and short-term activities required to execute the production plan effectively. It addresses issues like machine utilization, labor allocation, and task dependencies.

Example: Within the bakery's production plan, scheduling determines when to prepare dough, when to bake specific types of bread, and when to package the finished products.

 

Time Frame

Production Planning: It typically covers a longer time frame, ranging from months to years. It considers strategic goals, market trends, and capacity expansions.

Example: A furniture manufacturer plans its production for the upcoming year, considering factors like new product launches, factory expansions, and anticipated market demand.

 

Scheduling: It operates within a shorter time frame, ranging from days to weeks. It deals with the day-to-day or week-to-week execution of the production plan.

Example: Within the furniture manufacturer's production plan, scheduling determines the specific daily tasks for each work center, such as cutting wood, assembling parts, and applying finishes.

 

Level of Detail

Production Planning: It involves high-level decision-making and strategic considerations. It focuses on aggregate data and overall resource allocation.

Example: A clothing retailer plans its production at the product category level (e.g., shirts, pants, dresses) and determines the total quantities to produce based on historical sales and market trends.

 

Scheduling: It involves detailed operational planning. It breaks down tasks into smaller units, allocates resources, and considers the sequencing and timing of individual operations.

Example: Within the clothing retailer's production plan, scheduling determines the specific cutting, stitching, and finishing operations required for each garment.

 

Production planning deals with long-term, strategic decisions, determining what, how much, and when to produce, while scheduling focuses on short-term, operational decisions, specifying the sequence and timing of tasks required to execute the production plan efficiently. Production planning provides the overall roadmap, while scheduling determines the detailed steps to follow to achieve production targets.

 

Scheduling tools available for  high mix /low volume production environment

In a high mix/low volume production environment, where the production involves a wide variety of products in relatively smaller quantities, the scheduling requirements can be complex. Several scheduling tools can help optimize production and manage resources efficiently. Here are some commonly used tools for high mix/low volume production environments:

 

Finite Capacity Scheduling (FCS) Software

FCS software considers the finite capacity of resources, such as machines, labor, and materials, when scheduling tasks. It helps balance workloads, minimize bottlenecks, and optimize resource utilization. FCS tools provide visibility into the availability of resources and enable real-time scheduling adjustments based on dynamic factors.

 

Advanced Planning and Scheduling (APS) Systems

APS systems utilize algorithms and optimization techniques to create schedules that align with production constraints, customer demand, and resource availability. These tools consider factors like setup times, changeovers, material availability, and labor constraints. APS systems often integrate with enterprise resource planning (ERP) systems to provide a comprehensive production planning and scheduling solution.

 

Visual Scheduling Boards

Visual scheduling boards, often in the form of physical boards or electronic displays, provide a visual representation of the production schedule. They use color-coded cards, magnets, or digital graphics to represent different tasks, products, and resources. This visual approach helps operators and supervisors quickly understand the status of production, identify bottlenecks, and make scheduling decisions on the shop floor.

 

Drag-and-Drop Scheduling Software

Drag-and-drop scheduling tools allow users to interactively create and modify production schedules by dragging and dropping tasks or orders on a graphical interface. These user-friendly tools provide flexibility in adjusting schedules based on changing priorities, new orders, or unexpected events. They often integrate with other systems to gather real-time data for accurate scheduling decisions.

 

Kanban Systems

Kanban systems, originally developed in lean manufacturing, use visual cards or signals to control the flow of production. Each card represents a specific task or product, and the movement of cards triggers the scheduling of subsequent tasks. Kanban systems promote just-in-time production, enhance visibility, and enable efficient management of resources in high mix/low volume environments.

 

Production Control Software

Production control software assists in managing the execution of production schedules by tracking the progress of tasks, monitoring inventory levels, and providing real-time updates. It helps supervisors and operators make informed decisions to ensure tasks are completed as planned, manage material availability, and identify any deviations from the schedule.

 

It's important to note that the specific choice of scheduling tools depends on the organization's needs, budget, and IT infrastructure. Some companies may opt for customized solutions or combine multiple tools to address their unique requirements in a high mix/low volume production environment.

 

 

Difference Between Production Scheduling and Production Control

Production scheduling and production control are two distinct but interconnected aspects of managing the production process. Let's contrast them based on their objectives, scope, focus, and timing, along with relevant examples.

 

Objective

Production Scheduling: The primary objective of production scheduling is to create an optimized plan that specifies the sequence and timing of production tasks or operations. It aims to allocate resources effectively, minimize downtime, and ensure timely completion of orders.

Example: In a manufacturing plant, production scheduling determines the order and timing of operations, such as machining, assembly, and packaging, for different products or orders.

 

Production Control: The main objective of production control is to oversee and manage the execution of the production plan. It involves monitoring production progress, coordinating resources, addressing issues, and ensuring adherence to quality and time targets.

Example: In the same manufacturing plant, production control involves tracking the actual progress of operations, managing material flow, coordinating machine utilization, and addressing any deviations or bottlenecks in real-time.

 

Scope

Production Scheduling: It focuses on the planning phase of the production process, determining the sequence, timing, and dependencies of tasks. Scheduling considers factors such as available resources, capacity constraints, and order priorities.

Example: A production scheduler creates a weekly plan that specifies the order of operations and the required resources for each product, based on production capacity and customer demand.

 

Production Control: It deals with the actual execution and coordination of production activities. Control ensures that tasks are performed as scheduled, resources are allocated appropriately, and quality standards are maintained.

Example: A production controller monitors the progress of tasks, adjusts schedules if necessary, addresses equipment breakdowns or material shortages, and ensures that the production process stays on track.

 

Focus

Production Scheduling: It emphasizes optimizing the sequence and timing of tasks to maximize efficiency and minimize costs. Scheduling aims to balance workload, reduce setup times, and improve resource utilization.

Example: The production scheduler focuses on minimizing changeover times between different products to increase machine efficiency and throughput.

 

Production Control: It emphasizes real-time monitoring, coordination, and problem-solving during the production process. Control aims to address bottlenecks, resolve conflicts, and ensure that production targets are met.

Example: The production controller addresses unexpected equipment failures by reallocating resources, prioritizing critical orders, or coordinating maintenance activities to minimize downtime.

 

Timing

Production Scheduling: It occurs before the start of the production process and typically covers medium to long-term planning horizons. Scheduling establishes the initial plan and sets the foundation for production control.

Example: Scheduling determines the sequence and timing of operations for the upcoming week or month, providing an outline of the workload for production control.

 

Production Control: It happens during the actual production process, continuously monitoring and adjusting operations in real-time. Control responds to dynamic factors, such as machine breakdowns, material shortages, or changes in order priorities.

Example: Production control ensures that operators follow the established schedule, addresses unexpected issues, and manages changes or disruptions that occur during production.

 

Production Planning vs Production Control

 Let's contrast production planning and production control using the  bases of contrast: objective, scope, focus, and timing.

 

 

Objective

Production Planning: The objective of production planning is to develop a comprehensive and strategic plan that outlines what, how much, and when to produce to meet customer demand while optimizing resources. It involves analyzing forecasts, sales orders, inventory levels, and capacity to create a feasible production plan.

Example: A company's production planning team analyzes market demand, resource availability, and production capacity to create a monthly production plan, determining the overall quantities and product mix to produce.

 

Production Control: The objective of production control is to ensure the smooth execution of the production plan. It involves monitoring and coordinating production activities, addressing issues, and maintaining quality and efficiency throughout the production process.

Example: Production control teams oversee the actual production operations, track progress, coordinate resources, and make adjustments as needed to meet production targets and handle unexpected events.

 

Scope

Production Planning: It has a broader scope and long-term focus, encompassing strategic considerations such as production capacity, resource allocation, and overall production strategy. Planning takes into account factors like market trends, product mix, and capacity expansions.

Example: A manufacturing company's production planning department develops an annual production plan, considering factors such as anticipated market demand, new product launches, and factory expansions.

 

Production Control: It has a narrower scope and short-term focus, concentrating on the day-to-day execution of the production plan. Control involves managing the actual production activities, monitoring progress, coordinating resources, and addressing immediate issues.

Example: The production control team monitors the progress of tasks in real-time, coordinates machine usage, addresses bottlenecks, and manages material availability to ensure timely production and delivery.

 

Focus

Production Planning: It emphasizes strategic decision-making, resource optimization, and capacity planning. Planning aims to balance production volumes, minimize costs, and align production with demand forecasts.

Example: Production planning involves determining the optimal production sequence, identifying resource requirements, and optimizing the allocation of labor and materials across different products or orders.

 

Production Control: It focuses on operational management and execution. Control aims to ensure adherence to the production plan, manage resources efficiently, and address deviations or unexpected events in real-time.

Example: Production control involves monitoring the progress of tasks, coordinating machine utilization, managing material flow, and resolving immediate production issues such as equipment breakdowns or quality concerns.

 

Timing

Production Planning: It occurs before the start of the production process and covers medium to long-term planning horizons. Planning establishes the overall framework and sets the foundation for production control.

Example: Production planning occurs at the beginning of the fiscal year to determine the production goals, resource requirements, and preliminary schedules for the upcoming months.

 

Production Control: It takes place during the actual production process, in real-time. Control focuses on monitoring and managing the execution of production tasks, ensuring they align with the established plan.

Example: Production control continuously monitors the progress of operations, manages changes or disruptions, and adjusts schedules, resources, or priorities as necessary to maintain efficient production flow.

 

Production Scheduling Principles and  Methods for high mix /low volume Production Environment

In a high mix/low volume production environment, where the production involves a wide variety of products in relatively smaller quantities, several principles and methods can help optimize production scheduling. Here are some widely accepted principles and methods for high mix/low volume production environments:

 

Priority-based Scheduling

Prioritizing orders or tasks based on specific criteria such as customer due dates, order value, product profitability, or service level agreements. Assigning higher priority to time-sensitive or high-value orders ensures they receive prompt attention and are completed on time.

 

 

 

Capacity Analysis and Levelling

Analyzing the available capacity of resources, such as machines, labor, and materials, to identify bottlenecks or constraints. Levelling the workload across resources by smoothing out variations in demand can help avoid overloading certain resources while underutilizing others.

 

Setup Time Reduction

Reducing the time required to switch between different product setups or changeovers. Implementing techniques such as Single Minute Exchange of Dies (SMED) can minimize setup times, enabling more frequent changeovers and facilitating efficient production of diverse product mixes.

 

Kanban Systems

Implementing visual signals or cards, such as kanban cards, to control the flow of production. Kanban systems facilitate just-in-time production, enhance visibility, and enable efficient management of resources, ensuring the right products are produced at the right time in the right quantities.

 

Flexible Workforce

Building a flexible workforce capable of handling different tasks or operations. Cross-training employees and enabling them to perform multiple roles can improve scheduling flexibility and resource utilization, allowing for smooth adjustments to changes in product mix or demand.

 

Real-time Monitoring and Communication

Utilizing real-time data collection systems and communication channels to monitor the progress of production tasks, track inventory levels, and identify bottlenecks or issues as they arise. This enables timely decision-making, adjustments to schedules, and proactive problem-solving.

 

 

Lean Manufacturing Principles

Adopting lean manufacturing principles, such as waste reduction, continuous improvement, and value stream mapping. Eliminating non-value-added activities, optimizing material flow, and streamlining processes can improve efficiency and reduce lead times in high mix/low volume production environments.

 

 

 

Dynamic Scheduling

Implementing scheduling methods that allow for dynamic adjustments in real-time based on changing conditions or priorities. Dynamic scheduling considers factors like order cancellations, rush orders, resource breakdowns, or customer demand fluctuations, enabling quick adaptations to maintain efficient production flow.

 

Collaborative Planning and Communication

Promoting collaboration and communication between different departments involved in production planning and scheduling. Establishing cross-functional teams and regular meetings to share information, address challenges, and align priorities can help ensure a coordinated and effective scheduling process.

 

It's worth noting that the suitability and effectiveness of these principles and methods may vary depending on the specific characteristics and requirements of the high mix/low volume production environment. Organizations often tailor these approaches to their unique situations and continuously refine them through experimentation and continuous improvement efforts.

 

Differences in Production Scheduling Between high volume/low mix vs high mix /low volume production

Production scheduling differs significantly between high volume/low mix and high mix/low volume production environments. Let's compare the two in terms of key differences:

 

Order Characteristics

High Volume/Low Mix: In this scenario, the production primarily focuses on a limited number of standardized products or a single product. Orders are typically large in quantity and have a similar production process and lead time. The goal is to maximize efficiency and minimize production costs through economies of scale.

High Mix/Low Volume: In this case, production involves a wide variety of products with smaller quantities. Each product may have unique specifications, requiring different production processes, setups, and lead times. The goal is to accommodate diverse product requirements while ensuring flexibility and responsiveness to customer demands.

 

Scheduling Complexity

High Volume/Low Mix: Scheduling in high volume/low mix production is relatively straightforward as the focus is on optimizing production efficiency. The schedule can be repetitive and stable, with longer production runs for each product. Scheduling decisions primarily involve setting production rates, optimizing batch sizes, and minimizing changeover times.

High Mix/Low Volume: Scheduling in high mix/low volume production is more complex due to the diverse product mix and shorter production runs. The schedule needs to accommodate frequent changeovers, varied setups, and different lead times for each product. It requires careful sequencing, balancing workload, and efficient resource allocation to optimize production flow.

 

Resource Utilization

High Volume/Low Mix: In this type of production, resource utilization focuses on maximizing efficiency and throughput. Scheduling aims to keep machines and labor fully utilized by running longer production batches, reducing setup/changeover times, and minimizing idle time between batches.

High Mix/Low Volume: Resource utilization in high mix/low volume production emphasizes flexibility and adaptability. Scheduling aims to allocate resources effectively to accommodate diverse products and their unique requirements. It involves optimizing setups, coordinating labor and machine availability, and minimizing downtime during changeovers.

 

Lead Time and Delivery

High Volume/Low Mix: Lead times in high volume/low mix production are relatively predictable and stable. Due to longer production runs and optimized processes, orders can be fulfilled within consistent timeframes. Delivery schedules are usually based on standardized lead time calculations.

High Mix/Low Volume: Lead times in high mix/low volume production can vary significantly based on product complexity, setup requirements, and order prioritization. Scheduling needs to consider individual product lead times, customer due dates, and flexibility to accommodate urgent or high-priority orders.

 

Inventory Management

High Volume/Low Mix: Inventory management in high volume/low mix production focuses on maintaining sufficient stock levels to meet the consistent demand. Scheduling aims to balance production rates with inventory levels, often using strategies such as economic order quantities and just-in-time replenishment.

High Mix/Low Volume: Inventory management in high mix/low volume production requires careful planning and monitoring. Scheduling considers individual product demands, lead times, and resource availability to ensure the availability of raw materials and finished goods without excessive inventory holding costs.