Planning and Control in Manufacturing and Production.

Sample Answer

Explain Master Scheduling and the scheduling concept, including procedures that improve production planning performance

Master Scheduling is one of the most essential processes in production planning. It involves converting the overall production plan into a detailed schedule that specifies what products need to be produced, in what quantities, and when. The aim of a Master Production Schedule (MPS) is to ensure the right products are manufactured at the right time to meet customer demand while maintaining optimal resource utilisation (Vollmann et al., 2017).

In most manufacturing settings, the Master Schedule acts as the link between strategic planning and daily operations. It takes into account customer orders, forecasted demand, available inventory, and capacity limitations. The schedule must balance supply and demand, manage lead times, and avoid bottlenecks or overproduction.

For example, Toyota Motor Corporation uses its global MPS system to align production with customer demand across multiple plants. The company’s scheduling concept integrates data from suppliers, logistics, and dealers to achieve Just-in-Time (JIT) manufacturing. Toyota’s MPS helps reduce inventory costs and ensures components arrive only when needed, supporting lean production principles.

Procedures that improve scheduling performance include:

• Accurate forecasting: Predicting demand using historical data and market trends.

• Capacity planning: Ensuring available resources can meet the schedule’s requirements.

• Automation and ERP systems: Tools like SAP and Oracle streamline scheduling by integrating real-time data.

• Continuous feedback: Monitoring performance metrics and adjusting the schedule as necessary.

• Cross-functional collaboration: Encouraging communication between planning, production, and procurement teams.

Effective Master Scheduling improves planning accuracy, reduces waste, and enhances delivery performance. It acts as the backbone of production control by ensuring that each department works toward common objectives.

Evaluate how manufacturing and control systems are developed and monitored to improve production planning performance

Manufacturing and control systems have evolved from manual, paper-based processes to fully digital, integrated systems. Their main purpose is to coordinate materials, labour, and machines efficiently to achieve production goals.

Modern organisations rely on Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) tools that collect real-time production data to monitor performance. These systems track production orders, equipment utilisation, and quality control data, which allows managers to make informed decisions quickly.

Siemens, for example, employs a digital manufacturing system known as SIMATIC IT MES, which connects production lines with planning systems. This system allows Siemens to track performance indicators such as downtime, scrap rates, and production output. It helps identify inefficiencies early, leading to continuous improvement.

Monitoring production planning performance involves using several metrics, such as:

• Schedule adherence: Whether production follows the planned schedule.

• Cycle time: The time taken to produce a product from start to finish.

• Capacity utilisation: The percentage of available production capacity used effectively.

• Yield rate: The ratio of good units produced to total units started.

In modern lean environments, visual management tools like Kanban and Andon systems are also used to monitor workflow. Data collected from these systems can feed into performance dashboards, supporting transparency and accountability.

Overall, effective control systems help reduce downtime, improve forecasting accuracy, and strengthen coordination between planning and production departments.