In part-one of our comprehensive production planning series, we will delve into the importance of planning and provide actionable tips to optimize your production process.

Effective production planning acts as the strategic roadmap that guides a company toward optimizing its operations, minimizing costs, and aligning with overarching organizational goals. This core process provides the crucial ‘what’ and ‘how much’ in the production process, as it determines what to produce, but also the quantity needed to meet demand while managing resources effectively.

What’s the Difference Between Production ‘Planning’ and ‘Scheduling’?

Production planning and scheduling are two distinct processes within the manufacturing sector, even though they are often used interchangeably.

What is Production Planning?

Production planning is a strategic process that establishes what could be made and in what quantities. It revolves around setting targets and creating a detailed plan to meet customer demand, essentially providing the ‘what’ and ‘how much’ of the production process.

What is Production Scheduling?

On the other hand, production scheduling is more tactical and focuses on the ‘when’ and ‘how’ of production. It involves developing schedules for workers, equipment, and materials, and it is characterized by a short-term focus. Master schedulers convert the firm’s planned orders into work orders for distribution to the manufacturing floor for execution.

Dive deeper into our insights! Explore these other captivating Shoplogix blog posts:

• 3 Reasons Why Hanedashi Deserves Your Attention
• How to Implement Genchi Genbutsu for Effective Manufacturing Processes
• Full Guide on Machine Monitoring System in Manufacturing
• How to Implement Total Quality Management in Manufacturing in 10 Simple Steps
• Effective Gemba Walk Checklist for Manufacturers

5 Key Factors to Optimize Your Production Plan

1. Improve Your Forecasting

Refining forecasting is a vital step for manufacturers because the ability to accurately predict future demand enables manufacturers to make informed decisions about production volumes, timing, and resource requirements.

Dozens of forecasting techniques are available, each offering unique benefits. For example,  qualitative forecasting relies on expert opinion and market research, making it particularly useful when there’s no historical data or when launching a new product.

Enhancing forecast accuracy is an ongoing process that demands constant vigilance. This process involves analyzing historical data, using varied forecasting methods, updating predictions regularly, and leveraging departmental insights.

Here are some tips on how to improve your forecasting:

• Use technology, like forecasting software, to automate and improve the accuracy of your predictions.
• Regularly review and update your forecast models to reflect changes in the market or your business.
• Encourage collaboration between different departments to ensure all relevant factors are considered in your forecasts.
• Always analyze the accuracy of past forecasts to learn and improve future predictions.

2. Document Your Capacity

Production capacity refers to the maximum amount of work an organization can complete within a given period, serving as both a measure of a manufacturer’s physical capabilities and its ability to meet customer demands.

Without a clear grasp of production capacity, manufacturers run the risk of either falling short of demand or wasting resources through overproduction. Therefore, to strategically ensure that a company has sufficient resources to meet its customers’ demands is important. This involves determining the necessary production capacity to meet fluctuating product demands.

To calculate production capacity, you need to understand the maximum output that your processes can produce during regular working hours, typically measured in units produced per hour, shift, or day. Then, it’s important to adjust for factors such as maintenance time, employee breaks, and other non-productive times to determine the true production capacity.

Here are some tips for effectively managing your production capacity:

• Regularly review and update your capacity calculations to account for changes in production processes or market demand.
• Use capacity planning tools or software to help manage complex calculations and scenarios.
• Involve staff at all levels in capacity planning to ensure a comprehensive understanding of your production capabilities.
• Always consider potential future growth or contraction when planning capacity to maintain flexibility.

3. Standardize Steps and Time

By establishing a standard procedure for each operation and pinpointing the optimal amount of time needed for completion, manufacturers can create a predictable, repeatable process. This fosters more precise planning, waste reduction, and elimination of unnecessary variations that could interrupt the flow of production.

Without such standardization, manufacturers may face pitfalls such as inconsistent product quality due to varied procedures, inefficient resource utilization due to changing production times, and challenges in scheduling and forecasting.

When implementing standardization, consider these tips:

• Start by mapping out the entire production process, identifying each step, and determining the average completion time.
• Look for opportunities to streamline and optimize each step, simplifying where possible.
• Engage your employees in this process as they can offer valuable insights into potential improvements based on their hands-on experience.
• Ensure all standardized processes are well-documented and easily accessible to all staff.
• Regular training and reinforcement of these standards will help maintain consistency and efficiency in your operations.

4. Use Real-Time Monitoring

Real-time monitoring plays a transformative role in improving production planning in manufacturing. With the advent of modern technologies such as the Industrial Internet of Things (IIoT), big data analytics, Artificial Intelligence, and machine learning, real-time monitoring has become more accessible and effective than ever before.

A perfect illustration of this is the implementation of Shoplogix’s Smart Factory Suite, where you can gain real-time production performance. Shoplogix facilitated real-time data collection and live monitoring of production lines, leading to immediate insights into operations, improved decision-making, and proactive problem correction.

Here are some tips for implementing real-time monitoring in your manufacturing process:

• Invest in modern technologies like IIoT, big data analytics, AI, and machine learning to enable real-time monitoring.
• Use platforms like Shoplogix that offer real-time data collection, instant analysis, and comprehensive data visualization.
• Regularly review and analyze collected data to identify areas of improvement.
• Train your staff on using these technologies effectively to ensure maximum benefit.

5. Evaluate Your Risk Factors

Waste and Scrap

When scrap materials are discarded or rejected during production, they contribute to waste and pollution, depleting natural resources. High scrap rates can affect product output, operational costs, resource allocation, revenue rate, and overall production performance. A case study involving Shoplogix shows how real-time data can help evaluate and mitigate this risk. The plant used Shoplogix data to measure real-time KPIs such as Parts per Minute (PPM) on their Fly Trap Line, initially staffed by five employees.

This data analysis identified inefficiencies, enabling corrective actions that reduced the staff to two employees. While this change reduced output from 18 to 13 units per minute, it improved labor efficiency, resulting in savings of 10 cents per unit. The three reassigned employees were moved to other priority lines, helping reduce back ordered products and alleviate backlog issues.

To manage waste or scrap risk in manufacturing, regularly monitor and analyze real-time data, maintain machinery well, train employees to use resources efficiently, and consider reassigning employees for overall efficiency and cost savings.

High Labor Costs

High labor costs in manufacturing can stem from poor resource planning and reactive responses to low output. The common solution is adding more labor, assuming it will increase productivity. However, if the problem lies with machinery or materials, this method won’t be effective. Overstaffing can lead to inefficiencies, raising labor costs without improving productivity.

Poor resource planning can exacerbate such situations. If a mechanical issue is causing a slowdown, simply adding more people won’t help. It’s crucial to identify and address the root cause, which could involve machine maintenance or equipment upgrades. Similarly, material issues can impede productivity. In these cases, data analysis becomes vital. By identifying bottlenecks and areas for improvement, manufacturers can optimize labor costs and enhance operational efficiency.

Final Thoughts

We hope that these tips can provide you with a roadmap to your own production planning optimization. By harnessing the power of data, technology, and collaboration, manufacturers can enhance forecasting, align capacity, standardize processes, enable real-time monitoring, and mitigate risks.

The result? A streamlined production planning process that drives efficiency, quality, and cost savings through accurate projections, optimal resource allocation, consistency, visibility, and proactive problem-solving. With some strategic adjustments, manufacturers can transform their operations to maximize productivity and profitability.