What are the most popular supply chain planning models for manufacturing plants?

let review units and their Rolls: 1-Demand Planning Department: (Demand Forecast; Demand Replenishment; S&OP owner) 2- Supply planning Department: ( MRP and MPS owner; Production Planning ) 3- TPM (Total Productive Maintenance) Department: (Autonomous & Planned Maintenance; SHE Management; early equipment management; focused Improvement ) 4- Logistic: ( warehousing; fleet management) 5- Quality control 6- ERP system (To coordinate the processes between all the above units)

If I mention on a longer horizon then things cascade from a long term strategic planning which is a top down approach. Then the S&OP cycle starts with demand management which is an input to MPS. An aligned MPS, in addition to being a finalized make plan, is an input to MRP, capacity planning and then some of the feedback goes back to demand management also. Results from MRP go to factories or suppliers for further planning. No wonder we call it supply chain. every step is connected to next and previous ones to allow the flow of material and information.

Demand driven planning is key. However the extra leg would be to ensure a robust weekly S&op system to drive collaboration and sync efficiency of operations

The key is to determine the proper decoupling points in your Bill of Material AND applying the proper buffers at those levels. This does pose as a challenge if the BOM structures are extensive. Due to the real-time volatility of DDMRP, this system absolutely needs a robust software solution and regular maintenance of the master data in order to be successful. Excel spreadsheets alone WILL NOT suffice.

Mediante el posicionamiento estratégico de puntos de desacoplamiento, nuestros procesos son capaces de absorber la variabilidad. En la actualidad, día con día nuestras redes de suministro incrementan su complejidad; conflictos globales, el desabasto de materias primas y la pandemia, son solo algunos ejemplos del mundo en el que vivimos actualmente, el mundo VUCA. Si partimos de la premisa de que todo pronóstico es erróneo, anticiparse a todos estos cambios se asemeja mas a la tarea de un mago o un adivino. Es ahí en donde entra la necesidad de comenzar a dejar de trabajar exclusivamente con los pronósticos y empezar a utilizar la demanda real.

Modern S&OP, also called IBP Integrated Business Planning, considers not only the trade-off between demand and supply, but the financial outcome of forcing demand to be met. In my experience the cost of meeting demand with limited capacity increases as we exceed it, requiring additional activities such as purchasing external capacity. It is necessary to have the financial benefit of each possible decision. On one occasion we had to stop a marketing campaign because the production capacity had already been exhausted and the demand was very close to that capacity. Investing to sell more was an absurd expense because we could not sell more capacity. Financially, it did not add to the bottom line.

Make sure ERP implementations are well-staffed and funded, with the core team members having unwavering passion, drive, and focus from start to finish. Celebrate the victories. Make it fun. Take the time to thoroughly understand current processes and the structure/flow of the master/transactional data. It is a moot point if this is not considered as a high priority early on in the project. "Failure" tends to happen when shortcuts are taken in the process mapping and data cleansing steps. If you don't have a full grasp of what you have in front of you, how do you know where you want to go?

El uso de los sistemas ERP va más allá de la correcta selección de un sistema que se adapte a las necesidades del negocio. El buen uso de un ERP, requiere de una integración en nuestros procesos. Si existen silos en nuestra organización, dificilmente podremos sacar provecho a nuestras herramientas. De igual forma, es de suma importancia capacitar a nuestros equipos en el uso de estos sistemas para evitar caer en el mundo de la "Excelencia" y no porque seamos excelentes, sino porque usamos Excel para todo! Un alto porcentaje de las hojas de cálculo dentro de nuestras organizaciones presentan errores y estos a su vez se transforman en información errónea que utilizamos en nuestro día a día y que utilizamos para tomar decisiones.

Inventory Planning - Inventory Planning process is a medium term planning strategy in which product and material stocking policies and targets are determined based on customer service level to be fulfilled at downstream nodes, variability of demand placed on manufacturing plants and distribution centers, lead time and lead time variability of manufacturing of products, transfer of products and procurement of products. The targets and policies thus generated must drive the supply planning process.

Existen muchos modelos.. en mi pensar lo más importante es el balance.. un s&op o su versión más avanzada IBP con un balance entre demanda y ventas y una buena integración con la parte financiera.. pero esto debe conversarse con los modelos de producción y ahi las teorías lean y RFS son muy fuertes.. para tener los inventarios correctos..