What factors can cause production schedule inaccuracies?

1 Demand variability

One of the main sources of uncertainty in production scheduling is the variability of customer demand. Demand can fluctuate due to seasonal patterns, market trends, promotional campaigns, or unforeseen events. If the production schedule is not updated frequently or accurately to reflect the changes in demand, it can lead to overproduction or underproduction, resulting in excess inventory, stockouts, or missed deadlines. To cope with demand variability, plant engineers can use forecasting methods, such as moving averages, exponential smoothing, or regression analysis, to estimate the future demand and adjust the production schedule accordingly. They can also implement flexible production systems, such as lean manufacturing, that can respond quickly to demand changes by reducing setup times, batch sizes, and waste.

2 Resource constraints

Another factor that can affect the accuracy of production schedules is the availability and capacity of the resources involved in the production process. Resources include machines, tools, materials, labor, energy, and space. Any shortage, breakdown, or malfunction of these resources can disrupt the production schedule and cause delays, bottlenecks, or quality issues. To prevent or mitigate resource constraints, plant engineers can use techniques such as capacity planning, preventive maintenance, inventory management, and resource leveling to ensure that the production schedule matches the resource availability and utilization. They can also use simulation models, such as discrete event simulation or Monte Carlo simulation, to test the production schedule under different scenarios and identify potential risks and opportunities.

3 Human factors

A third factor that can influence the accuracy of production schedules is the human factor. Human factors include the skills, knowledge, motivation, and behavior of the workers and managers involved in the production process. Human factors can affect the production schedule positively or negatively, depending on how well they are aligned with the production goals and expectations. For example, human factors can improve the production schedule by enhancing productivity, quality, innovation, and collaboration. However, human factors can also degrade the production schedule by causing errors, conflicts, absenteeism, or turnover. To optimize the human factor, plant engineers can use methods such as training, communication, feedback, incentives, and empowerment to ensure that the workers and managers have the necessary competencies, information, and motivation to execute the production schedule effectively and efficiently.

4 External factors

A fourth factor that can impact the accuracy of production schedules is the external factor. External factors include the environmental, economic, social, political, and legal conditions that affect the production process. External factors can create opportunities or threats for the production schedule, depending on how well they are anticipated and managed. For example, external factors can enhance the production schedule by providing new markets, technologies, or regulations that favor the production process. However, external factors can also impair the production schedule by imposing new challenges, competitors, or restrictions that hinder the production process. To cope with external factors, plant engineers can use tools such as SWOT analysis, PESTEL analysis, or scenario planning to assess the external environment and its implications for the production schedule. They can also use strategies such as diversification, outsourcing, or alliances to reduce the dependence on or exposure to external factors.

5 Schedule complexity

A fifth factor that can affect the accuracy of production schedules is the schedule complexity. Schedule complexity refers to the degree of difficulty or uncertainty involved in developing and executing the production schedule. Schedule complexity depends on factors such as the number of products, processes, resources, and constraints involved in the production process, as well as the degree of interdependence, variability, and dynamism among them. Schedule complexity can increase the chances of errors, conflicts, or deviations in the production schedule, as well as the time and effort required to create and update it. To reduce schedule complexity, plant engineers can use methods such as standardization, simplification, modularization, or integration to streamline the production process and its components. They can also use software tools, such as ERP, MRP, or APS, to automate and optimize the production scheduling process.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?