← All expertise
Expertise
Production planning
Monthly programme to daily schedule for two assembly lines.
4,650units a day planned
6–7 h → ~1 hmonthly export plan
Day to day
Assistant Manager PPC at Atlas Honda: two frame lines, supporting a 4,650-unit-a-day build programme.
- Turned model and colour demand and export orders into the monthly build programme for a 4,650-unit daily output.
- Split it into lot-sized weekly and daily schedules (lots of about 200 units), sequenced by model and colour.
- Checked capacity day by day: working days, holidays, reduced hours, shutdowns and overtime rules.
- Tracked schedule adherence and recovered lost units by resequencing or overtime.
- Functionally supervised four PPC staff.
The planning cycle
A month of production planning, before any project.
- Monthly
Set the programme
- Turned model and colour demand and export orders into the monthly build programme.
- Checked it against capacity day by day: working days, holidays, reduced hours, shutdowns and overtime rules.
- Agreed the mix with Sales, Production and Materials before it was fixed.
- Planned export lots, packing and dispatch.
Capacity modelExport plan - Weekly
Schedule the lines
- Split the programme into lot-sized weekly and daily schedules for two assembly lines (lots of about 200 units).
- Sequenced models and colours to suit the line and material arrival.
- Checked MRP planned orders against BOM requirements before they reached the line.
- Looked seven days ahead for components that would run short.
MD04MD05CS11 - Daily
Keep the line running
- Converted planned orders and released production orders.
- Ran the shortage report across about 1,100 active parts.
- Expedited gaps with Supply Chain, Stores and the Karachi plant: by air, fast-track or container.
- Tracked schedule adherence and recovered lost units by resequencing or overtime.
CO01CO02COOISShortage model - Month-end
Close and reconcile
- Confirmed output and closed the month’s production orders.
- Reconciled physical stock against SAP and moved non-conforming stock to Quality Inspection or Blocked.
- Reviewed adherence and units lost, and carried the gaps into next month’s plan.
- Kept planning master data right: BOMs, routings, work centres and production versions.
CO11NMB51MB52C223
How it runs
- DemandModel and colour demand, export orders and working days into a monthly build plan.
- MaterialsPlanned orders checked against BOMs and MRP output.
- CapacityLot sizes, sequencing, cycle time and overtime fitted to two frame lines.
- Execution & closingOrders created, confirmed and tracked; monthly closing fed the next plan.
What I know
Planning methods
Where I learned it
What I improved
5 scenariosday-level capacity modelProduction Capacity & Scenario Planning Model →2 linesovertime without extra van runsAssembly Shift, Overtime & Transport Optimisation →6–7 h → ~1 hmonthly export planExport Production Planning Automation →1 hourearlier start to use solarSolar Utilisation & Production Schedule Optimisation →
Planning should turn complexity into action.
Open to Production Planner, Materials Planner, Production Controller and Supply Chain Planning roles in the UK.