Last updated on 2024年9月11日

Struggling to synchronize your production schedule with supplier lead times?

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In chemical engineering, the synchronization of production schedules with supplier lead times is a critical aspect of supply chain management. You're likely familiar with the frustration of delays and inefficiencies that can arise when these elements are not in harmony. The process requires a strategic approach to align the manufacturing of chemicals, materials, and products with the availability of raw materials and components supplied by various vendors. Achieving this balance is essential for maintaining a smooth and cost-effective operation.

本文章的要点总结

Implement forecasting tools:

Use advanced planning and scheduling (APS) software to integrate with your enterprise resource planning (ERP) system. This tech gives you a clear view of production schedules and supplier times, helping you adapt on the fly.
Buffer stock strategy:

Set aside a buffer stock, especially for materials with a limited shelf life or in supplier-dominated markets. This approach, about 30% extra stock, safeguards against unforeseen delays and keeps your operation running smoothly.

本摘要由 AI 和以下专家提供支持

Nelson Nan

CPSM,Toastmaster member,Global…
Rohit Batra

Supply Chain Manager at Andrews Meat…

1 Analyze Data

To start, thoroughly analyze your current production data and supplier lead times. This means looking at the average time it takes for suppliers to deliver materials and comparing it with your production cycle. Understanding these timelines allows you to identify bottlenecks and anticipate potential delays. By doing so, you can adjust your production schedule accordingly, ensuring that you have the necessary materials on hand when you need them, without resorting to costly last-minute orders or excess inventory that ties up capital.

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Nelson Nan

CPSM,Toastmaster member,Global Commodity Manager
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Technically，we have to set up certain buffer stock based on Chemical Shelf Life and unpredictable forecast and suppose ~30%buffer setup to mitigate risk because Chemical (adhesive )is supplier dominated markert like DOW，Henkel who have strong tone cause we have very limit power to influence to supplier

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Rohit Batra

Supply Chain Manager at Andrews Meat Industries, JBS Australia
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Data analysis and providing insights to supplier re their performance, delivery patterns, and variability. By evaluating historical data on lead times, production planners can identify trends in supplier reliability and pinpoint where delays are likely to occur. This allows for more accurate forecasting, better alignment of production timelines, and the ability to adjust order quantities or safety stock levels to mitigate the impact of unpredictable lead times. Ultimately, data-driven insights enable more informed decisions, improving overall supply chain coordination.

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2 Forecast Needs

Next, forecast your production needs with precision. Use historical data, market trends, and sales projections to estimate future demand for your products. This forward-looking approach helps you communicate with suppliers ahead of time, allowing them to adjust their schedules to meet your requirements. It's crucial to establish a collaborative relationship with your suppliers to ensure they understand your business needs and are willing to work with you to achieve optimal results.

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Rohit Batra

Supply Chain Manager at Andrews Meat Industries, JBS Australia
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Forecasting is crucial for staying ahead of potential delays with suppliers. By predicting demand accurately, one can plan orders in advance, giving suppliers enough time to meet requirements. It also helps you maintain the right amount of stock without over-ordering, which can tie up resources. Good forecasting means you're less likely to be caught off guard by sudden spikes in demand or supply chain disruptions, keeping everything running smoothly. Finally, if you are well aware of the issue, sometimes micromanagement can mitigate the risks.

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3 Implement Tools

Implementing the right tools can make a significant difference. Consider using advanced planning and scheduling (APS) software that integrates with your enterprise resource planning (ERP) system. These tools can provide real-time visibility into both your production schedule and supplier lead times, enabling you to make informed decisions quickly. With these systems in place, you can react to changes in demand or supply disruptions with agility, minimizing the impact on your operations.

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4 Streamline Processes

Streamlining your internal processes is equally important. Evaluate each step of your production line to identify inefficiencies that could be causing delays. Look for ways to reduce setup times, improve workflow, and optimize equipment usage. By fine-tuning these processes, you can shorten production cycles and reduce the lead time needed from suppliers, which in turn can help synchronize schedules more effectively.

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5 Build Relationships

Building strong relationships with your suppliers is vital. This goes beyond mere transactions; it's about creating partnerships where both parties are invested in each other's success. Regular communication, sharing of forecasts, and joint problem-solving can foster a sense of trust and collaboration. When suppliers are closely aligned with your production goals, they are more likely to accommodate your scheduling needs and work proactively to prevent disruptions.

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6 Manage Inventory

Lastly, managing your inventory strategically is a key component. Implementing a just-in-time (JIT) inventory system can reduce waste and storage costs, but it requires precise timing of supplier deliveries. To make JIT work, you need a clear understanding of your production schedule and must communicate this effectively to your suppliers. Maintaining a buffer stock for critical materials can also mitigate risks associated with unexpected delays or increased demand.

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Struggling to synchronize your production schedule with supplier lead times?

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1 Analyze Data

2 Forecast Needs

3 Implement Tools

4 Streamline Processes

5 Build Relationships

6 Manage Inventory

Chemical Engineering

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