KMP 5903

Manufacturing Operation
Management
Weekly Presentation
Master Scheduling
Group 7
1) Mohd Nasrull B. Abd Rahman (GS21504)
2) Edwin Chan (GS21416)

KMP 5903 Manufacturing Operation

Management
 Content
• Scheduling
• Master Scheduling
• Axapta's Master Planning Software
• Master Schedule Types
• Scheduling Manufacturing Operations
• High-Volume Systems
• Gantt Load Chart
• Loading
• Sequencing
• Scheduling Difficulties
• Scheduling Service Operations
• Cyclical Scheduling
• Service Operation Problems
• Scheduling Workload United Airlines (Video)
• New process implementation, conversion schedule McDonald s (Video)

KMP 5903 Manufacturing Operation

Management
 Scheduling
• Scheduling: Establishing the timing of the
use of equipment, facilities and human
activities in an organization
• Effective scheduling can yield
– Cost savings
– Increases in productivity

KMP 5903 Manufacturing Operation

Management
 Master Scheduling
• Master scheduling is used for:
– demand management
– scheduling production
– validating the production schedule
– managing the production schedule
• The schedules generated by master
scheduling as input to other manufacturing
functions, such as material requirements
planning and rough-cut capacity planning.
KMP 5903 Manufacturing Operation
Management
 Axapta's Master Planning
Software
Master scheduling helps
to calculate what needs
b) to be purchased and
produced to fill a sales
order:
c) to deliver the amount
ordered on the date
scheduled, and to
generate transfers
between warehouses if
needed.

KMP 5903 Manufacturing Operation

Management
 Master Schedule Types
Master Demand Schedule (MDS)
• The MDS is a statement of demand and contains details
of the anticipated shipment schedule
• The master demand schedule provides an extra level of
control that allows to view and modify statement of
demand before creating a detailed production schedule.
• Some of the demand types that the MDS considers are:
– item forecasts
– spares demand
– sales orders
– internal requisitions
KMP 5903 Manufacturing Operation
Management
 Master Schedule Types
Master Production Schedule (MPS)
• The MPS is a statement of supply required to meet the
demand for the items contained in the MDS.
• The master production schedule defines the anticipated
build schedule for critical items.
• An effective master production schedule provides the
basis for order promising and links the aggregate
production plan to manufacturing by specific items,
dates, and quantities.

KMP 5903 Manufacturing Operation

Management
 An example of a (very) simplified
Master Production Schedule for
'Product A'.

KMP 5903 Manufacturing Operation

Management
 Scheduling Manufacturing
Operations
JAN FEB MAR APR MAY JUN
High-volume
Build A

Intermediate- A Done

volume Build B

B Done
Low-volume Build C

Service C Done
On time!
Build D
operations Ship

KMP 5903 Manufacturing Operation

Management
 High-Volume Systems
• Flow system: High-volume system with
Standardized equipment and activities
• Flow-shop scheduling: Scheduling for high-
volume flow system

Work Center #1 Work Center #2 Output

KMP 5903 Manufacturing Operation

Management
 High-Volume Success
Factors
• Process and product design
• Preventive maintenance
• Rapid repair when breakdown occurs
• Optimal product mixes
• Minimization of quality problems
• Reliability and timing of supplies
KMP 5903 Manufacturing Operation
Management
 Scheduling Low-Volume
Systems
• Loading - assignment of jobs to process
centers
• Sequencing - determining the order in
which jobs will be processed
• Job-shop scheduling
– Scheduling for low-volume
systems with many
variations
in requirements

KMP 5903 Manufacturing Operation

Management
 Gantt Load Chart
• Gantt chart - used as a visual aid for
loading and scheduling
Work Mon. Tues. Wed. Thurs. Fri.
Center
1 Job 3 Job 4
2 Job 3 Job 7
3 Job 1 Job 6 Job 7
4 Job 10

KMP 5903 Manufacturing Operation

Management
 Loading
• Infinite loading
• Finite loading
• Vertical loading
• Horizontal loading
• Forward scheduling
• Backward scheduling
• Schedule chart
KMP 5903 Manufacturing Operation
Management
 Sequencing
• Sequencing: Determine the order in which
jobs at a work center will be processed.

• Workstation: An area where one person

works, usually with special equipment, on
a specialized job.

KMP 5903 Manufacturing Operation

Management
 Sequencing
• Priority rules: Simple heuristics
used to select the order in
which jobs will be processed.

• Job time: Time needed for

setup and processing of a job.

KMP 5903 Manufacturing Operation

Management
 Scheduling Difficulties
• Variability in
– Setup times
– Processing times
– Interruptions
– Changes in the set of jobs
• No method for identifying optimal
schedule
• Scheduling is not an exact science
• Ongoing task for a manager
KMP 5903 Manufacturing Operation
Management
 Minimizing Scheduling
Difficulties
• Set realistic due dates
• Focus on bottleneck operations
• Consider lot splitting of large jobs

KMP 5903 Manufacturing Operation

Management
 Scheduling Service
Operations
• Appointment systems
– Controls customer arrivals for service
• Reservation systems
– Estimates demand for service
• Scheduling the workforce
– Manages capacity for service
• Scheduling multiple resources
– Coordinates use of more than one resource
KMP 5903 Manufacturing Operation
Management
 Service Operation
Problems
• Cannot store or inventory services
• Customer service requests are random
• Scheduling service involves
– Customers
– Workforce
– Equipment

KMP 5903 Manufacturing Operation

Management
 Scheduling Workload United Airlines

KMP 5903 Manufacturing Operation

Management
 References
• Book of Operations Management, William J. Stevenson 8th edition

• http://www.mbsadvisor.com/axapta/masterscheduling.htm

• http://www.mcts.com/Master-Scheduling.html

• http://www.realtimesw.com/manufacturing/master_scheduling.htm

• http://www.master-scheduling.com/

KMP 5903 Manufacturing Operation

Management
KMP 5903 Manufacturing Operation
Management