Skip to Content
MANUFACTURING
Back to overview/Planning & MRP

Plan at the cadence the plant can answer.

Master production scheduling and MRP driven by orders and forecast, constrained by real work-centre capacity — producing a plan the floor can execute rather than one it will absorb informally.

The problem

Most regional plants plan monthly against demand that moves weekly, and the plant absorbs the difference through informal expediting nobody has costed.

Planning against infinite capacity produces a schedule that is arithmetically valid and operationally impossible — which is why adherence, not the plan, is the number to watch.

Core workflow

Demand to released work order.

01
Demand
Firm orders and forecast consolidated by period.
02
MPS
Master schedule by product family and period.
03
MRP
Material requirement exploded through the BOM.
04
Capacity check
Work-centre load against available hours.
05
Balancing
Sequence adjusted, bottleneck protected.
06
Release
Work orders and purchase requisitions issued.
What it covers

Planning

Master production scheduleForecast and firm order mixPlanning horizon and bucketsMake-to-order and make-to-stockRolling plan review

Materials

MRP explosionLead times and safety stockPurchase requisition generationShortage and expedite listSubcontract requirement

Capacity

Work-centre capacity modelFinite and infinite loadingBottleneck identificationShift and calendar patternsLoad levelling
Operational outcomes
88%
Schedule adherence
−34%
Expediting cost
−22%
Raw material days of cover
Weekly
Planning cadence, not monthly

Ranges observed on Al Jawad engagements. Targets agreed in assessment.

Re-plan one month against real capacity.

We rebuild last month's schedule with finite capacity and show which orders were never achievable.