Supply Chain: How to make planning (MPS, RCCP, MRP, DRP)

Explore the bill of materials as a hierarchical recipe and shopping list for assembling a product. It supports cost estimates and materials requirements planning (MRP) within ERP systems.

Explore how to design manpower schedules under legal constraints, 100% capacity utilization, and budget limits, comparing two 12-hour shifts with four teams, weekly and biweekly rotations, and weekend coverage.

Integrate supply chain planning across departments to optimize resources, achieve the least-cost delivery on time, and boost customer satisfaction through responsive lead time.

Learn how integrated supply chain planning uses MPS, MRP, and DRP to translate demand into production, material needs, and distribution decisions, while considering lead times, shelf life, and warehouse capacity.

Explore master production scheduling and rough cut capacity planning to determine quantities, safety stock, and beginning on hand targets from forecasts, and validate feasibility against a 60-shift limit with RCCP.

Balance seasonality in master production scheduling through RCCP by advancing heavy items (X4, X5, X6) using goal seek to keep monthly shifts near 56–60, smoothing demand.

Identify capacity bottlenecks, near bottlenecks, and non bottlenecks; design systems to minimize bottleneck effects, maximize bottleneck utilization, and improve overall output and cycle time.

Analyze capacity bottlenecks on a two-product line (A and B) across mixing, processing, freezing, and packing, using per-stage output and utilization to reveal the bottleneck.

Identify and mitigate the shifting bottleneck by establishing a profit-driven product mix solved with linear programming to maximize profit, while improving bottleneck reliability and reducing capacity-killer items.

Explore material requirements planning (MRP) to balance inventory, lead times, and safety stock. Learn to compute gross and net requirements, plan orders, and manage backdated POs across BOM-driven materials.

Explore how distribution requirement planning determines inventories, quantities, and locations to meet anticipated demand and satisfy customers, using a factory–main warehouse–distribution center network to optimize fulfillment rate and responsiveness.

Explore distribution requirement planning (DRP) through two regional DC scenarios, linking safety stock, in-transit quantities, and planned receipts with lead times to optimize main DC supply and orders.

Monitor shelf life through policy planning, documentation, and system controls to guard against waste and financial loss, using first-in, first-out and batch-level tracking to prioritize near-expiry items.

Master shelf life management by batch-level planning to align consumption with expiration and reduce disposal. Compute end on hand and consumption plans for multi-batch inventories.

Master shelf life management to protect profits by reducing waste with accurate forecasting and shelf life formulas, applying world-class manufacturing principles to achieve zero expired materials.

Evaluate system performance with quantitative metrics to clarify availability and supply performance, and distinguish stock at period start from stock available during the period against forecast.

Compute weekly availability and net availability to derive monthly supply performance. Compare sales percentage with net availability, taking the maximum to evaluate category of SKUs KPI against a 95% target.

Boost sales and save costs by applying integrated supply chain planning at home, leveraging supply chain management concepts for practical use.