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Table of Contents

Table of Contents Instructor Guide © 2012 APICS Confidential and Proprietary

Instructor Guide

© 2012 APICS Confidential and Proprietary

Table of Contents Instructor Guide © 2012 APICS Confidential and Proprietary
Table of Contents Instructor Guide © 2012 APICS Confidential and Proprietary
Table of Contents

Table of Contents

Participant Workbook Page

Table of Contents

Session 1—Master Planning of Resources

The Manufacturing Planning and Control System

1-9

Manufacturing and Service Industry Objectives

1-9

Role of Manufacturing Planning and Control

1-11

Manufacturing Planning Hierarchy……………

1-15

Role of Planning Software in MPC

1-21

Factors Affecting MPR System Design.…………

1-23

Master Planning of Resources…………………

1-29

Direction Setting: Strategic and Business Planning

1-29

Demand Management

1-33

Sales and Operations Planning… ………………………………………………………

1-41

Master Scheduling………………………

1-45

Distribution Planning……

1-47

Master Planning of Resources

Master Planning of Resources

Session 2—Forecasting Demand

Demand Forecasting Concepts…

2-7

Forecasting Framework………………………

2-7

Managing the Forecast… …………

2-17

Forecasting Techniques

2-29

Factors Affecting the Forecast.……

2-29

Qualitative Forecasting Techniques

2-39

Quantitative Intrinsic Techniques

2-45

Quantitative Casual Techniques

2-59

Collaborative Planning, Forecasting, and Replenishment

2-63

Table of Contents

Table of Contents

Participant Workbook Page

Session 3—Demand Management and Customer Service

Evaluating Forecast Performance…

3-7

Guidelines for Evaluating Forecasts

3-7

Outcomes of Forecast Evaluation…

3-9

Determining Forecast Error……

3-9

Standard Deviation……….……

3-21

Customer Relationship and Order Management

3-25

Customer Relationship Management (CRM)

3-25

Customer Order Management

3-33

Effective Customer and Internal Communication…………………………………………………

3-39

Order Delivery Performance Measurement

3-41

Customer Service and Safety Stock………

3-49

Purpose of Safety Stock…

3-49

Customer Service Levels………………………………………………………………………………

3-51

Calculation of Safety Stock…………………………………………………………………………….

3-53

Customer Service Policy and Performance Targets………………………………………….…….

3-61

Master Planning of Resources

Master Planning of Resources

Session 4—Distribution Planning

Distribution Network Planning……….………

4-7

Distribution Channel Design Considerations

4-7

Network Configuration……………………………………………… …

4-17

Transportation and Distribution Center Site Decisions…………………………………………….

4-29

Distribution Replenishment Planning……………

4-37

Product Forecasting…………………………………

4-37

Replenishment Planning Approaches……………

4-43

Replenishment Planning Linkages to S&OP and Master Scheduling…

4-61

Measuring Performance………………

Distribution System Performance Measures…

4-69

4-71

Table of Contents

Table of Contents

Participant Workbook Page

Session 5—Sales and Operations Planning

S&OP Introduction…………

5-7

Major Attributes.…………………………………

5-7

S&OP Relationships….……………………………….…………………

5-9

S&OP Fundamentals………

5-11

Management Considerations.…

5-13

Guiding the Business………………………………

5-13

Roles and Responsibilities………………………………………………………………………

5-19

Key Planning Factors………………………………………………………………………………

5-21

The S&OP Process……………………….……

5-25

S&OP Process Outcomes…………………

5-25

Monthly Executive S&OP Process Steps… ……………………………………………………

5-27

Developing and Validating the Production Plan

5-31

Production Planning Methods……………

……………………………………………………

5-31

Make-to-Stock S&OP Plan… ……………………………………………………………………

5-33

Developing a Make-to-Stock S&OP Grid………………………………………………………….

5-35

Financial Evaluation of Level and Chase………………………………………………

……….

5-41

Developing a Make-to-Order S&OP Grid……………………………

5-47

…………………………. Resource Planning…………………………………………………………………………………

5-57

Master Planning of Resources

Master Planning of Resources

Session 6—S&OP and Master Scheduling

Introduction…

…………

6-7

Transition from Sales and Operations Planning… …………………………………………

….

6-7

Master Scheduling Objectives…………

6-7

Role in Manufacturing Planning and Control……………………………………………………

6-9

Maintaining the Master Schedule………………………………………………………………….

6-11

Major Influences on Master Scheduling…………

6-13

Business Environment… …………

Master Scheduling Process.…………

6-13

6-19

Introduction…………………………………………

6-19

Maintaining the Stability of MPS…

6-39

Table of Contents

Table of Contents

Participant Workbook Page

Session 7—Managing the Master Schedule

Management Considerations………………

……………………………………

7-7

The Balancing Act………………… …………………………………………….………………….

7-7

The Role of the Master Scheduler….………………………………………………………………

7-9

The Role of the Senior Executive…………………………………………………………………

7-11

Planning and Coordinating Changes………………………………………………………………

7-13

Maintaining the Integrity of the Master Schedule…………………………………………………

7-27

Assemble-to-Order Master Scheduling……

7-31

Bills of Material

7-31

Planning Bills of Material……… …………………………………………………………………

7-33

Two-Level Master Scheduling Demonstration and Problems………………………….……….

7-43

Reviewing Capacity Requirements

7-55

Rough-Cut Capacity planning

7-55

RCCP Process……

7-57

Possible Solutions…… …

7-63

Overload and Underload…

7-65

Revised MPS and RCCP Report…………………………………………………………………

7-67

Advanced Planning and Scheduling (APS)

7-69

Approach to Capacity Planning

7-69

APS Process

7-71

Measuring Master Scheduling Performance

7-73

Policies and Methods

7-73

Problem Indicators

7-75

Performance Measures……………………………………………………………………………

7-77

Master Planning of Resources

Master Planning of Resources

Session 8—Case Studies

Cash Studies

8-7

Production Planning Methods……… …………………………………………….……………….

8-7

Master Scheduling in a Make-to-Order Environment…………………………………………….

8-13

Master Scheduling in a Make-to-Stock Environment…………………………………………….

8-19

Appendix

Progress Check Answer Sheet

A-1

Bibliography…………

A-2

Course Evaluation

A-3

Index

Index

Index 1