Production Planning and Scheduling Training Course

Module One: How Technology and New Software Are Changing Manufacturing

This module provides a high-level, practical introduction to the technologies redefining modern manufacturing. Learners explore Industry 4.0, smart factories, cloud computing, IoT, ERP/MRP systems, robotics, 3D printing, blockchain, predictive analytics, AI, immersive technologies, and advanced materials. The focus is on understanding what these technologies are, how they work together, and how they drive productivity, flexibility, visibility, and competitive advantage—without getting lost in unnecessary technical jargon.

Module Two: Manufacturing Planning and Control

This module explains how manufacturing organizations translate customer demand into controlled, repeatable production processes. Participants learn how customers influence, process categories, order qualifiers, market forces, and economic indicators shape manufacturing decisions. The module also introduces process analysis and mapping tools that help identify bottlenecks, improve information flow, and support data-driven decision-making across the operation.

Module Three: Sales and Operations Planning (S&OP)

This module focuses on aligning sales, operations, finance, and leadership through an effective S&OP process. Learners gain insight into demand planning, consensus meetings, resource balancing, and plan development while addressing real-world challenges such as capacity constraints and the productivity impact of temporary labor. The outcome is a clear understanding of how S&OP creates stability, accountability, and cross-functional alignment.

Module Four: Forecasting

This module demystifies forecasting and demonstrates how it supports more informed supply-chain and production decisions. Participants explore qualitative and quantitative forecasting methods, time-series analysis, regression, and explanatory models. Special emphasis is placed on understanding forecast error and key accuracy measures so managers can improve forecasts, reduce risk, and make more informed planning decisions.

Module Five: Accountability

This module establishes the management systems that drive consistent performance on the shop floor. Learners examine the development of SOPs, span of control, performance indicators, KPIs, OEE, and performance reviews. The module also addresses workforce considerations such as extended shifts and their operational impact, helping managers balance productivity, safety, and accountability.

Section Two: Production Management

Module One: Production Planning, Scheduling, and Control

This module defines the core roles, responsibilities, and systems that keep production on track. Participants learn how production managers, planners, schedulers, supervisors, and maintenance planners collaborate through Production Activity Control (PAC). Best practices such as job planning, kitting, staging, feedback loops, and proactive planning are emphasized to help organizations move from reactive to controlled operations.

Module Two: Inventory Management

This module builds a practical foundation in inventory control and decision-making. Learners explore inventory costs, service-level tradeoffs, EOQ, reorder points, safety stock, turnover, and key inventory metrics. The goal is to help managers balance availability, cash flow, and operational efficiency while maintaining accurate inventory records.

Module Three: Asset Tracking

This module introduces modern asset and inventory visibility tools used across manufacturing and warehousing. Participants learn how SKUs, AIDC technologies, barcodes, QR codes, RFID, voice systems, and barcode readers support accuracy, speed, and traceability. The focus is on understanding capabilities, standards, and selection criteria rather than technical configuration.

Module Four: Just-In-Time and Lean Production

This module explores proven lean production methods for reducing waste and improving flow. Learners examine JIT principles, Kanban systems, Andon boards, and Total Productive Maintenance (TPM), as well as strategies for managing uncertainty in production environments. The module emphasizes practical application and continuous improvement.

Module Five: Theory of Constraints

This module teaches managers how to identify and manage system bottlenecks using the Theory of Constraints. Participants learn the TOC five-step process and apply root cause analysis techniques to eliminate recurring problems. The focus is on improving throughput, stabilizing operations, and driving measurable performance gains.

Module Six: Purchasing and Distribution

This module highlights how purchasing and distribution decisions directly affect cost, service, and profitability. Learners explore vendor compliance agreements, purchasing accountability, logistics performance, vendor-managed inventory, and service-level agreements. The module reinforces the importance of strong supplier and distribution management in supporting operational excellence.

Conclusion: Words to the Wise

The course concludes by addressing the human side of manufacturing change. Participants learn practical strategies for convincing management that change is necessary and for influencing leaders who are resistant to new approaches. The emphasis is on communication, credibility, and the presentation of data-driven alternatives that lead to informed decisions and long-term improvement.

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