Planning and control of production processes

Production Planning & Scheduling

Your partner for the optimal planning and scheduling of production processes to ensure competitiveness.

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The importance of strategic Production Planning and Scheduling

Efficient production planning and schedule control (PPS) forms the intelligent link between dynamic market demand and value-adding manufacturing. It is essential for manufacturing companies to confidently manage the growing variety of product variants as well as conflicting objectives, such as shorter lead times amidst high cost pressures. As a measurable outcome, organisations working with ebp-consulting benefit from a dramatic improvement in on-time-in-full (OTIF) performance, significantly reduced lead times and the targeted reduction of blocking excess stock. To secure these efficiency gains in the long term, it is essential to implement systematic decoupling strategies and flexible, capacity-based planning approaches that highlight potential bottlenecks in advance.
   

“Anyone who fails to consistently align their production processes with flexible demand patterns will rapidly lose competitiveness in complex market environments – data-driven control is the only guarantee of resilience.”

Kasra Nayabi
Managing Partner at ebp-consulting

Challenges & Benefits of Production Planning and Scheduling

The ever-increasing variety of product variants, coupled with unpredictable demand cycles, places a massive strain on conventional planning models that focus solely on machine utilisation. As a result, manufacturing companies struggle with spiralling stocks of work-in-progress, a lack of process transparency and constant, resource-intensive ad hoc interventions in the production process. Added to this is the often flawed system integration of ERP and MES landscapes, which makes a reliable, real-time demand-capacity balancing virtually impossible. ebp-consulting GmbH understands these complex challenges from in-depth practical experience and delivers precisely tailored, high-performance solutions to overcome these operational hurdles in a future-proof manner.

Lack of transparency due to isolated data silos

Many production networks suffer from a fragmented IT landscape in which planning data does not flow seamlessly between ERP, MES and APS systems. This leads to production plans that are unrealistic to implement and a lack of visibility regarding impending capacity bottlenecks. ebp-consulting’s methodology specifically breaks down these silos and implements an end-to-end data architecture for maximum planning reliability.

Inefficient inventory management with high variance

Traditional high-volume production in diversified product portfolios inevitably leads to high stock levels at the wrong time, whilst at the same time there are shortages elsewhere. This misallocation of capital and space hampers liquidity and slows down the entire lead time of the supply chain. With ebp-consulting’s consumption-driven pull concepts, these excess stocks can be systematically reduced without jeopardising product availability.

Lack of adaptability to market changes

Rigid order approvals prevent a rapid response to changing customer priorities, which drastically reduces the On-Time-In-Full (OTIF) rate. Without systematic decoupling strategies, market fluctuations have an unfiltered impact on the production floor, leading to constant changeovers. The tried-and-tested expertise of ebp-consulting enables the establishment of flexible control systems that effectively cushion these disturbances.

The benefits of well-thought-out production planning and control at a glance

  • Improved delivery reliability (On-Time & In-Full, ‘OTIF’)
  • Efficient utilisation of capacity and resources in production, manufacturing and assembly
  • Early identification of potential bottlenecks in production and assembly, with the opportunity to take proactive countermeasures
  • Reduction in lead times
  • Reduction of excess stock whilst simultaneously improving product availability
  • Reduction in work-in-progress stock
  • Increased transparency in production processes
  • Stabilisation of production and assembly processes
  • Minimisation of unplanned emergency measures (“firefighting”)
       

Optimise your production planning now

Logistics consulting in Stuttgart, Munich and Dortmund

Our key focus areas in production planning and control:

These strategic and operational highlights form the foundation of any successful process restructuring and are essential for the optimisation of the value chain. They are based on proven principles of knowledge transfer and create a lasting, structured basis for operational efficiency. Using measurable indicators, we unlock the full potential of production control.

Sales & Operations Planning (S&OP)

Cross-departmental synchronisation of sales forecasts and production capacities is the most effective way to prevent planning errors. Companies should utilise rolling planning horizons to identify discrepancies between sales targets and manufacturing realities at an early stage. From numerous consultancy projects, we know that a properly established S&OP process reduces firefighting in production many times over.

Flexible Production Control Based on Lean Principles

The transition from error-prone push systems to an efficient pull mechanism aligns production strictly with actual customer consumption. By identifying the lead process, the entire material flow can be stabilised and synchronised with the takt time. Our ebp experts recommend a rigorous reduction in batch sizes to drastically shorten lead times and optimise changeover times.

Capacity-Based Planning and Demand Alignment

Realistic order scheduling requires comprehensive knowledge of set-up times, equipment availability and staff capacity. Defining clear constraints prevents production from being overloaded with unrealistic targets. In practice, we rely on end-to-end IT solutions that visualise bottlenecks before they lead to production stoppages.

Synchronisation of Pre-production and Final Assembly

Uncoordinated production stages inevitably lead to massive stocks of work-in-progress (WIP), which tie up expensive production space. Intelligent sequencing links these areas so that materials flow into the assembly line on a just-in-time basis. In our projects, we establish systematic FIFO lines and ‘supermarkets’ to ensure precisely this seamless transition.

Order Fulfilment Strategies (Build-to-Order vs. Stock)

The correct allocation of product groups to suitable manufacturing strategies (such as Assemble-to-Order) determines the efficiency of the entire supply chain. Highly volatile products require different planning approaches to stable, standard items. We support companies in carrying out this segmentation on a data-driven basis and in precisely defining the decoupling points.

System Specification for ERP, MES and APS

Even the best planning concept will fail if the IT systems cannot support the required logic. A clear definition of requirements and parameters is essential for the digital transformation of manufacturing. We support our clients from the impartial selection of systems through to the seamless implementation of the new planning architecture.

Approach to Production Planning and Control with ebp-consulting

ebp-consulting’s methodical consulting approach combines in-depth analysis with pragmatic implementation expertise. We transform theoretical planning models into practical, operational reality by perfectly aligning people, processes and IT systems. In doing so, we draw on cross-industry best practices to establish sustainable and crisis-proof control mechanisms.
  

Optimise your production planning now

 

Strategy definition and potential analysis

In this crucial first step, ebp-consulting analyses consumption patterns, identifies bottlenecks and defines the key levers for optimisation. What sets this apart is that we do not merely tackle symptoms, but put the structural setup of the manufacturing strategy to the test. In this way, ebp-consulting lays a data-driven foundation that guarantees maximum value creation, independent of short-term market trends.

Process Design and Concept Development

The ebp approach focuses here on the bespoke development of flexible production planning and control (PPS) concepts that integrate seamlessly into the company’s lean philosophy. Unlike traditional consultancies, we avoid abstract theory and instead build resilient control logic that functionally mirrors the reality of everyday factory operations. We define specific batch sizes, cycle times and capacity limits that stabilise the system operationally. This in-depth level of detail significantly distinguishes our design phase and ensures the high practical applicability of the new processes.

System Integration and Change Management

Successful restructuring requires more than just new process flowcharts; it demands full integration into IT systems and the minds of employees. ebp-consulting oversees the specification of APS, MES or ERP systems and ensures cultural change within the workforce through intensive change management. We set ourselves apart from other consultancy approaches by providing on-site operational support throughout the implementation process until measurable success is achieved (go-live). In this way, we ensure that the optimised planning logic is applied sustainably in day-to-day management and that the return on investment is reliably secured.

Further Consulting Focus Areas as a management consultancy Production:

  • Production strategies

  • Production logistics planning

  • Lean produc­tion

    • Enhancement of machine utilisation (OEE optimisation)
    • Optimisation of retooling, SMED/quick changeover
    • Implementation of value stream analysis and design
    • Introduction of flow manufacturing (one-piece flow)
    • Implementation of Toyota production principles: One-piece flow, pull principal, zero defects, clocked production
    • Application of lean methods/techniques Poka yoke, jidoka, minomi, chaku chaku
    • Application and implementation of Six Sigma

  • Assembly planning

  • MTM analyses in Production

Areas of Focus and Types of Production Planning and Control

Order Management and Order Centres

Consolidating administrative and control activities within dedicated order centres accelerates order processing and reduces interface losses. Best practice here involves the use of interdisciplinary teams that consolidate sales and production data in a central IT dashboard. This organisational structure enables customer enquiries to be validated significantly faster and scheduled into the system as feasible production orders.

Production Levelling (Heijunka)

Heijunka is an essential area of focus for smoothing out fluctuations in customer call-offs and operating production at a steady, predictable pace. A stable process is absolutely essential for successful implementation, and this is managed transparently – either physically or digitally – via Heijunka boards. The absolute highlight of this sub-area is the significant stabilisation of the entire supply chain, which has a positive impact right through to external suppliers.

Tool Management in Planning

The direct integration of tool management into the overarching planning process prevents costly machine downtime caused by missing or defective equipment. Modern MES systems utilise intelligent tracking for this purpose and integrate tool uptime directly into capacity planning. Companies that master this area operationally significantly increase their Overall Equipment Effectiveness (OEE) whilst simultaneously reducing ongoing maintenance costs.

Implementing production planning and scheduling excellently

Holistic consultancy project (end-to-end)

This model offers you a complete turnkey package, ranging from the initial data analysis to the operational commissioning of the new control logic. You benefit from a seamless project process, as our experts orchestrate all phases of the transformation and take full responsibility for achieving the objectives. This enables you to minimise internal project risks and secure a measurable increase in efficiency across the entire supply chain.

Flexible Deployment of Experts / Interim Management

Overcome critical resource bottlenecks or specific knowledge gaps quickly and effectively by calling on our highly qualified logistics experts as and when required. Our interim managers immediately assume operational responsibility, stabilise critical production phases and implement necessary changes without a lengthy induction period. This flexible transfer of expertise strengthens your team precisely where the need for methodological support in planning is currently greatest.

Strategic Quick Check / On-site Audit

In this highly focused format, we analyse your existing planning landscape through a standardised on-site audit to identify structural weaknesses and untapped potential. Within a very short time, you will receive a robust roadmap with prioritised immediate actions that will have a direct positive impact on your cash flow and operational delivery reliability. The Quick-Check thus provides you with a sound basis for decision-making regarding future, secure investments in your control processes.

Reference Projects of ebp in the Field of Development and Optimisation of Production Planning and Scheduling:

  • Design, development, and implementation of a capacity-based production planning and control system for a food manufacturer – including integration into the supporting IT systems
  • Development and implementation of a concept for synchronising pre-assembly steps and final assembly to reduce semi-finished goods inventory for a manufacturer of technical components for the furniture and kitchen industry
  • Definition of suitable production concepts for product manufacturing (Build-to-Order versus Build-to-Stock), and development of a production planning and control approach for a manufacturer of chemical and pharmaceutical products
  • Development and implementation of a production planning and scheduling concept to reduce lead times and ensure on-time delivery of customised products for an electronics manufacturer
  • Development of a production planning and scheduling concept to reduce lead times and ensure on-time delivery of customised goods for a manufacturer of electronic components
  • Development and implementation of an optimised planning concept for production and assembly of high-speed internet cables based on the pull principle and its integration into a Sales, Inventory, and Operations Planning process
  • Development and implementation of a planning and control concept for a 4-stage production and assembly process of painted bumpers at an automotive supplier (injection moulding, paint shop, pre-assembly, and final assembly)

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Your contact person

Irene Kocher

T +49 711 3917030

info@ebp-consulting.com

Frequently asked questions on Production Planning and Scheduling

How quickly does the introduction of new PPS concepts pay for itself?

The payback period (ROI) for a strategic restructuring of the PPS is generally pleasingly short and often less than twelve months. As consumption-based control mechanisms drastically reduce stocks of semi-finished and finished goods, tied-up capital is released extremely quickly. At the same time, shorter lead times and the elimination of changeover costs noticeably reduce operating costs. Companies should bear in mind that the initial commitment of resources to internal workshops is very quickly offset by the elimination of ‘fire-fighting’ in production.

Are new IT systems (ERP, MES, APS) absolutely essential for efficient production control?

It is not always necessary to replace the entire software landscape immediately in order to achieve significant optimisation gains in production control. Often, enormous planning potential can already be realised through consistent process streamlining, precise master data maintenance and the intelligent reconfiguration of existing ERP systems. However, should the existing IT architecture be too restrictive, we guide the system selection process methodically, reliably and in a completely vendor-neutral manner. We minimise potential concerns about lengthy IT implementations through robust specifications and strict, profitability-focused project management. An excellent process landscape must always be finalised before the actual system implementation.

What is the difference between manufacturing planning and production planning?

Production planning acts as an overarching, strategic-tactical process that holistically aligns the entire value chain, from material requirements planning to cross-plant capacity control. In contrast, manufacturing planning is an operational sub-discipline that focuses very specifically on the technical, spatial and detailed temporal execution of the actual manufacturing steps within the plant. Whilst production planning thus primarily determines what, when and in what quantities must be produced to meet customer demand, manufacturing planning defines exactly how, with what and on which specific machines the physical processing of the workpieces takes place.

Do in-house PPS optimisation projects tie up too many resources?

A professional consultancy project is structured precisely to ensure that the day-to-day operational work of your key staff remains protected as much as possible at all times. We rely on focused project phases and highly efficient workshop formats, in which we condense the necessary knowledge rather than creating ineffective, long-term burdens. Thanks to our strong, analytical focus on independent data preparation, we significantly relieve your team of time-consuming preparatory work. Many clients initially fear a strain on resources, but quickly realise that the methodical guidance provided by ebp-consulting creates operational freedom rather than hindering it.

How does ebp-consulting ensure that the new planning concepts are embraced by staff?

Technological and procedural excellence in planning remains completely ineffective if there is no cultural change on the shop floor and in production planning. We actively involve your specialist staff in the solution-finding process right from the initial analysis, which immediately allays concerns and massively increases their buy-in to the new standards. Our accompanying change management programme also includes practical training and intensive on-the-job coaching throughout the entire ramp-up phase. Through this close, empathetic support, the new understanding of control is firmly embedded in the company’s DNA, effectively preventing a return to old planning patterns.

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