Program Overview
This training is tailored to manufacturing and supply chain professionals seeking hands-on expertise in Production Planning and Control (PPC) using structured planning tools like Master Production Scheduling (MPS) and Material Requirements Planning (MRP). The program demystifies how demand signals translate into detailed production and procurement plans, ensuring inventory balance, capacity utilization, and delivery reliability. Participants will engage with simulations and case exercises to align BOM structures, lead times, and batch sizing with real-world planning scenarios. Special emphasis is placed on ERP/MRP system logic, planning accuracy, and shop-floor integration.
Features
- Build and manage MPS based on forecast, capacity, and order patterns.
- Use MRP logic to align material availability with production timelines.
- Identify and resolve planning failures due to incorrect BOMs, lead times, or batch sizing.
- Integrate PPC with ERP systems to ensure smooth execution and shop-floor control.
Target audiences
- Production Planners
- Supply Chain Professionals
- Operations Managers
- ERP Analysts
- PPC Executives
Curriculum
- 6 Sections
- 30 Lessons
- 2 Days
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- Introduction to PPC5
- 1.1Concepts: PPC Objectives, Key Elements, Planning Horizons
- 1.2Keywords: Push vs Pull, Finite vs Infinite Scheduling, Routing, Loading
- 1.3Situational Focus: Aligning production to fluctuating demand
- 1.4Real-life Insight: Batch-based production failure due to improper sequencing
- 1.5Exercise: Map your current PPC flow vs best-in-class PPC cycle
- Master Production Schedule (MPS)5
- 2.1Concepts: Time Fences, Firm vs Planned Orders, ATP (Available to Promise)
- 2.2Keywords: Make-to-Stock (MTS), Make-to-Order (MTO), FAS (Final Assembly Schedule)
- 2.3Situational Focus: Balancing plant loading for short lead time SKUs
- 2.4Real-life Insight: FMCG plant reducing changeovers via MPS refinement
- 2.5Exercise: Build a basic MPS for a 2-week cycle (Excel-based)
- Material Requirements Planning (MRP)5
- 3.1Concepts: BOM Explosion, Netting Logic, Lot Sizing
- 3.2Keywords: Lead Time Offsets, Pegging, Safety Stocks, Rescheduling Horizon
- 3.3Situational Focus: Stockouts despite high FG inventory – wrong input in MRP
- 3.4Real-life Insight: ERP-MRP misalignment led to raw material bottlenecks
- 3.5Exercise: Simulate an MRP run and track exception messages
- Shop Floor Execution & Control5
- Integration with Procurement & Inventory5
- Advanced Planning – ERP/MES/APS Integration5
- 6.1Concepts: Real-time PPC, Feedback Loops, Rescheduling
- 6.2Keywords: APS, ATP/CTP, Time Bucket Planning, Plant Digital Twin
- 6.3Situational Focus: Real-time plan update in high-mix low-volume setup
- 6.4Real-life Insight: Migration to SAP APO enabled dynamic load balancing
- 6.5Exercise: Real vs Planned Schedule variance workshop
Instructor
