MASTER PRODUCTION SCHEDULE
The Master Production Schedule (MPS) defines the type and volume of each product that is to be produced within the planning horizon. The MPS is a detailed plan that specifies the exact timing for the production of each unit. Master production schedules are also used in scheduling various stages of production, depending on the type of operations. For instance, the MPS of make-to-order organizations deals only with end-items or final products, and not components and sub-assemblies. On the other hand, the MPS for assemble-to-order organizations concentrates on scheduling the major components that are assembled to make a product after orders are received. MPS is based on an estimation of the overall demand for the end product. A final assembly schedule is developed only when customer orders are received. Functions of an MPS are described below:
Translate aggregate plans
The master schedule is a manufacturing plan, which breaks up planned total production of the firm into groups of products or product lots. The sizes of the lots are determined in such a way that the products are economical to produce and utilize firm's facilities and resources at an optimal level. The aggregate plan sets a level of operations that balances market demand with the material, labor and equipment capabilities of the firm, whereas the master schedule is more detailed and translates the aggregate plan into a specific number of individual products to be produced in specific time periods at specific workstations.
Evaluate alternative schedules
Planners use computerized production and inventory control systems with simulation capabilities to evaluate alternative master schedules. Once all the alternatives are evaluated, the detailed material and capacity requirements are identified, and the exact lead times and delivery schedules are also determined by the planners. The simulations even suggest how increased demand for one product can affect the production schedule of other products.
Identify material requirement
The prime input for a material requirements planning system is the master schedule. Once the master schedule is drawn up, it alerts the material requirement planning system to produce or purchase the necessary components that are needed to meet the requirements of final assembly schedules.
Generate capacity requirements
Capacity requirement planning needs inputs from the material requirement plan, which in turn, is directed by the master schedule. So, the master schedule is a prerequisite for capacity planning. The master schedule reflects the most economical usage of labor and equipment capacities. If the capacity available does not satisfy the requirements of the master production schedule, either the production capacity or the MPS is revised.
Effectively utilize capacity
The master production schedule assigns loads for labor and equipment based on the requirements. The load report takes into account of the individual product requirements and available resources in assigning load to individual workers, equipment and workstations. The objective is to fully utilize the available capacity.
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