Production planning systems
We implement demand-planning and production-planning systems that align what the market asks for with what the company makes: less stock, less waste and more reliable delivery times.
The starting point
When demand forecasting and production planning don't talk to each other, the company swings between overproduction and stock-outs, between overloaded departments and idle time. Integrating the two systems makes better use of capacity and lets the company respond to the market quickly and precisely.
What the company gains
- Demand and production aligned, with no excess or shortage of stock
- Less idle time and better use of resources
- Lower operating costs
- Faster deliveries and more satisfied customers
The process
How the engagement works
- 01
Analysis of the production flow
We map the path from customer order to delivery: sales forecasts, bills of materials, routings, department capacity, inventory and supply lead times.
- 02
Demand forecasting
We set up a demand planning process that combines historical data, the order book and sales intelligence, shared by sales and production.
- 03
Planning and scheduling
We define the rules for planning production against real capacity and for managing stock at levels consistent with demand, integrated with the ERP.
- 04
Measurement and improvement
We introduce indicators for service level, inventory and capacity use, and a regular plan review cycle, so the system improves over time.
Signs it is the right time
- The warehouse is full of what is not needed and short of what is
- Delivery dates promised to customers are often missed
- Some departments are overloaded while others stand idle
- Planning lives in spreadsheets managed by a single person
- Sales and production work from different forecasts
What the company keeps
- Map of the production flow and its bottlenecks
- Demand forecasting process shared by sales and production
- Planning rules based on real capacity
- Inventory management policies
- Service level, inventory and capacity indicators
Frequently asked questions
Do we need to change our ERP?
Not always. Many ERPs have planning features that are under-used. We first assess what can be achieved with the existing systems; if extra tools are needed, we integrate them with the ERP.
Does it work for make-to-order production?
Yes. For make-to-order production the focus shifts from sales forecasting to managing capacity and delivery dates, but the method is the same.
Who needs to be involved?
Sales, production, purchasing and logistics: planning only works if every function works from the same numbers. That is why the process is shared from the start.
Let's talk about your company.
An initial, confidential and no-obligation conversation to understand where your organisation stands today and where it can go.