Capacity & Labor Planning Consulting
Manufacturing is on a downward trend after eight months of PMI (purchasing manager’s index) below 50. It dropped to 46 in June. China’s manufacturing also shrank for a third month in a row to a PMI of 49. Yet manufacturers backlogs remain relatively robust in many industries, leading executives perplexed on what to do about capacity shortfalls.
How Do You Benefit from Capacity & Labor Planning?
Sales & Marketing
Sales and Marketing leaders will gain high levels of service for their customers with on-time-in-full (OTIF) levels in the high 90’s, shorter lead-times, and high ratings on customer scorecards. They also will gain improved levels of responsiveness to customer needs and confidence in new product rollouts.
Engineering
For engineer-to-order (ETO) and configure-to-order (CTO) businesses, Engineering leaders will gain visibility into workload requirements to support drawings, customer approvals, and bill of material designs. They will be able to plan for the appropriate level of engineering capacity and capabilities.
Manufacturing
Manufacturing leaders will gain visibility into work center, machine, equipment, tooling, maintenance, staffing, and training requirements so that they can plan accordingly. They will also gain visibility into the master production schedule so that they can optimize run sizes with changeovers and costs.
Purchasing
Purchasing leaders will gain visibility into raw material, component, ingredient, and outside processing requirements so that they can work with suppliers to set up the appropriate programs and contracts to meet customer requirements. Suppliers will have visibility to capacity and scorecards.
Logistics
Logistics leaders will gain visibility into storage, warehousing, handling, picking, packing, shipping, transportation, returns, and equipment requirements so that they can plan accordingly. As gaps arise, service and cost options can be analyzed to expand capacity or capabilities as needed to support customers.
Finance
Finance leaders will gain visibility into sales forecasts, engineering and manufacturing plans, capital expenditure needs, purchase forecasts, staffing and support resource requirements, logistics forecasts, and inventory projections. Thus, they will have revenue, cost, profitability, and cash flow projections.
Planning
Planning leaders will gain visibility into the demand plan, sales orders, quotes, replenishment orders, and work order status so that they can develop the best master production schedule (MPS) to optimize customer service, operational efficiency and working capital. They will gain high service levels and increased margins.
Blog posts for Capacity & Labor Planning
As companies are concerned about declining backlogs, they are searching for solutions to keep top talent and stop the bleeding. Executives are using SIOP to maximize margins while preparing to scale up successfully for a manufacturing resurgence.
One of the most common issues executives raise is the inability to secure reliable delivery dates upfront when communicating with customers and taking orders. Clearly, this bottleneck results in frustration and the potential for lost orders as customers demand reliable delivery dates, stable lead times, and expedited performance.
The supply chain is in a constant state of disruption. As we discussed on Supply Chain Chats, simple backup plans are no longer enough. In fact, you can look at recent events and determine if a backup is sufficient. Starting with the pandemic, of course, most if not all companies didn’t have a sufficient enough backup plan.
