Topic: Demand planning

Improvements in 2016 &

Scope for 2017
Gemba: Coimbatore Factory

Haroon Basha
Production planning- Improvement - 2016
- 7 Day rolling plan introduced where there is no rigid planning pattern earlier

Production plan (weekly) with Supplier Shipping

PSI ( Monthly )
current week + 3 weeks Schedule

Rolling window from C+7d onwards

M T W T F S S M T W T F S S M T W T F S S M T W T F S S
PLND
Plan entry on Thu
+ Supplier stocking policy changed from
Plan entry on Fri MTS to MTO
+ Dynamic plan changed form 8th day
Plan entry on Sat onwards .
+ Material requirement generated Manually
PLan entry on mon on day to day basis

Slide 2
Material Execution & Planning- Daily Activities
Monday Tuesday Wednesday Thursday Friday

Production feasibility PSI process Weekly production

checking consensus meeting Weekly MIS
( 3rd week only )

Frontier Weekly Forecast to suppliers

Meeting based on MPS / PSI Daily delivery schedule Supplier delivery
Weekly MIS for C+2 weeks schedule confirmation

Supplier delivery
confirmation and Risk identification

Daily production plan

- Draft

Daily Production sequence meeting for D+1 day

Order Management / Order confirmation activities

Kanban Adjustment/Kanban triggering

Routine & Urgent Shpt follow up

Collaboration With sourcing ; F2F Collaboration Meeting; Supplier Performance Mgmt

Slide 3
Production planning-Scope of improvement-2017 -Heijunka
- Currently the DTA production is based on the Batch Qty , resulting in cycle time loss
- Level loading opportunity is identified and working towards to implement it in mid of 2017.
- Targeted to save cycle time by 2.5 mins for Frontier units.

Current cycle Time = 10.6 Mins

Planned Cycle time = 7.5 Mins

Slide 4