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Master Scheduling
Part 11 of 12

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Lean Manufacturing Articles




The master schedules are the key to creating high-qual­ity schedules at all levels. They must be valid in terms of lead time, capacity, and stability. On-time delivery of the master schedules leads to excellent customer service and conformance to budgeted costs. It is not good enough to just practice master scheduling and make MPS deci­sions in the framework of a system. To get these ben­efits, it is important to measure performance in planning and executing the plans. Unfortunately, many compa­nies practice master scheduling, but do not apply good measurements to their process.



It is not unusual for companies to report high levels of customer service. After all, there is an extreme focus on this measurement at all levels of the organization and even personal involvement in some customer relation­ships. There is a difference in the means of attaining this service from company to company. Some do it by planning well and executing their plans. Others do it by carrying high inventories to cover for poor planning and execution. Still others do it with heavy expediting and overtime costs. The difference between the first approach and the others is often a result of their measurements. When the focus is entirely on the final customer service measurement and not on the factors that contribute to excellent performance and eventually lead to excellent service, the result can be chaotic and costly.



Apply a few key measurements to the master schedules and you can achieve excellent service at a reasonable cost. These measurements are:

     MPS Stability-The number of MPS orders that
change compared to the total number of MPS orders.

     MPS Summary—Does the sum of the master sched­
ules for a family equal the production plan for that
family? (Have we diverged from the resource plan?)

     MPS Lead-rimes—What percent of the master sched­
ules are scheduled at less than lead-times (time

     MPS Execution—What percent of MPS orders are
delivered on time and at full quantity?

To Be Continued

For balance of this article, click on the below link:

Lean Manufacturing Articles and click on Series 14

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