World Class Master Scheduling: Best Practices and Lean Six Sigma Continuous Improvement

Chapter 9: Measuring the Master Production Scheduling Process

OVERVIEW

Measurements are the feedback loop to both performance and improvement in general. The master production schedule (MPS) is one of the most important processes in an enterprise resource planning (ERP) business system and therefore should have robust measurements to drive that performance and improvement. Several metrics can help with this goal. The first one most organizations use is the weekly schedule attainment measure. This metric is done by locking the schedule (for measurement purposes only) at the end of the week. During the following week, changes are monitored and documented to understand accuracy and root cause.

The following are some reasonable rules to incorporate into your measurement process:

  1. The metric is facilitated by the percent of complete orders that are completed in the week they were scheduled according to the latest weekly schedule (plan of record from the end of last week).

  2. There is a separate schedule (and metric) for each product line in the business.

  3. Each schedule is locked at the end of each week for the following week (for measurement purposes only; schedule will actually be revised as necessary).

  4. The consolidated plant or business metric is the accumulated percentage of orders completed within the week scheduled. No averaging of product line performance averages.

  5. If rule 4 above is followed, weighting of values within the metric is not necessary. If there are some product lines with numerous small orders and others with few large orders, it doesn t make any difference!

  6. The planned schedule and actual comparison is to...