Programa MPR Master Planning of Resources – APICS CPIM Objetivos: A aChain é empresa APICS Channel Partner e realizará o curso de revisão do módulo MPR Master Planning of Resources . No módulo MPR o participante será capaz de identificar, avaliar, desenvolver e melhorar os processos do S&OP – Sales and operations planning, forecasting, demand planning, distribution planning, replenishment e DRP Distribution Requirements Planning, aprenderá todos os detalhes do Master Schedule, MPS – Master Production Schedule, ATP – Available-To-Promise e FAS – Final Assembly Schedule. O curso foca em profundidade sobre todas as políticas, estratégias, objetivos e restrições de recursos no nível agregado (S&OP) e desagregado (MPS). O candidato ainda desenvolverá planos alinhados entre demanda e supply com a validação da capacidade. Este módulo é fundamental para as áreas relacionadas com S&OP e demand planning. Tópicos: Session 1-Master Planning of Resources Session 2-Forecasting Demand Session 3-Demand Management and Customer Service Session 4-Distribution Planning Session 5-Sales and Operations Planning Session 6-S&OP and Master Scheduling Session 7-Managing the Master Schedule Session 8-Case Studies aChain - APICS - MPR conteúdo programático (http://www.achain.com.br/)

1. Table of Contents
MPR CPIM
© 2014 APICS Confidential and Proprietary
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company

3. Table of Contents
Participant Workbook Page
Table of Contents
Session 1—Master Planning of Resources
The Manufacturing Planning and Control System ........................................................ 1-9
Manufacturing and Service Industry Objectives ....................................................................... 1-9
Role of Manufacturing Planning and Control ........................................................................... 1-11
Manufacturing Planning Hierarchy ............................................................................................ 1-15
Role of Planning Software in MPC ............................................................................................. 1-21
Factors Affecting MPR System Design ...................................................................................... 1-23
Master Planning of Resources ....................................................................................... 1-29
Direction Setting: Strategic and Business Planning ................................................................. 1-29
Demand Management ............................................................................................................... 1-33
Sales and Operations Planning ................................................................................................. 1-41
Master Scheduling ..................................................................................................................... 1-45
Distribution Planning .................................................................................................................. 1-47
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
© 2014 APICS i Instructor Guide Version 4.3

4. Master Planning of Resources
Session 2—Forecasting Demand
Demand Forecasting Concepts… .................................................................................. 2-7
Forecasting Framework .............................................................................................................. 2-7
Managing the Forecast ............................................................................................................... 2-17
Forecasting Techniques ................................................................................................. 2-29
Factors Affecting the Forecast ................................................................................................... 2-29
Qualitative Forecasting Techniques........................................................................................... 2-39
Quantitative Intrinsic Techniques .............................................................................................. 2-45
Quantitative Causal Techniques................................................................................................. 2-59
Collaborative Planning, Forecasting, and Replenishment ....................................................... 2-63
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 4.3 ii © 2014 APICS

5. Table of Contents
Participant Workbook Page
Session 3—Demand Management and Customer Service
Evaluating Forecast Performance ................................................................................. 3-7
Guidelines for Evaluating Forecasts .......................................................................................... 3-7
Outcomes of Forecast Evaluation ............................................................................................. 3-9
Determining Forecast Error........................................................................................................ 3-9
Standard Deviation..................................................................................................................... 3-21
Customer Relationship and Order Management .......................................................... 3-25
Customer Relationship Management (CRM) ............................................................................ 3-25
Customer Order Management ................................................................................................... 3-33
Effective Customer and Internal Communication .................................................................... 3-39
Order Delivery Performance Measurement .............................................................................. 3-41
Customer Service and Safety Stock .............................................................................. 3-49
Purpose of Safety Stock ............................................................................................................. 3-49
Customer Service Levels ............................................................................................................ 3-51
Calculation of Safety Stock ........................................................................................................ 3-53
Customer Service Policy and Performance Targets ................................................................. 3-61
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
© 2014 APICS iii Instructor Guide Version 4.3

6. Master Planning of Resources
Session 4—Distribution Planning
Distribution Network Planning ....................................................................................... 4-7
Distribution Channel Design Considerations ............................................................................ 4-7
Network Configuration ................................................................................................................ 4-17
Transportation and Distribution Center Site Decisions ............................................................ 4-29
Distribution Replenishment Planning .......................................................................... . 4-37
Product Forecasting .................................................................................................................... 4-37
Replenishment Planning Approaches ....................................................................................... 4-43
Replenishment Planning Linkages to S&OP and Master Scheduling ...................................... 4-61
Measuring Performance ................................................................................................. 4-69
Distribution System Performance Measures ............................................................................ 4-71
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 4.3 iv © 2014 APICS

7. Table of Contents
Participant Workbook Page
Session 5—Sales and Operations Planning
S&OP Introduction .......................................................................................................... 5-7
Major Attributes .......................................................................................................................... 5-7
S&OP Relationships ................................................................................................................... 5-9
S&OP Fundamentals .................................................................................................................. 5-11
Management Considerations. ........................................................................................ 5-13
Guiding the Business ................................................................................................................. 5-13
Roles and Responsibilities ......................................................................................................... 5-19
Key Planning Factors .................................................................................................................. 5-21
The S&OP Process .......................................................................................................... 5-25
S&OP Process Outcomes ........................................................................................................... 5-25
Monthly Executive S&OP Process Steps… ................................................................................ 5-27
Developing and Validating the Production Plan ........................................................... 5-31
Production Planning Methods ................................................................................................... 5-31
Make-to-Stock S&OP Plan .......................................................................................................... 5-33
Developing a Make-to-Stock S&OP Grid ................................................................................... 5-35
Financial Evaluation of Level and Chase .................................................................................. 5-41
Developing a Make-to-Order S&OP Grid… ................................................................................ 5-47
Resource Planning… .................................................................................................................. 5-57
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
© 2014 APICS v Instructor Guide Version 4.3

8. Master Planning of Resources
Session 6—S&OP and Master Scheduling
Introduction ..................................................................................................................... 6-7
Transition from Sales and Operations Planning .......................................................................6-7
Master Scheduling Objectives ....................................................................................................6-7
Role in Manufacturing Planning and Control ............................................................................6-9
Maintaining the Master Schedule ..............................................................................................6-11
Major Influences on Master Scheduling ....................................................................... 6-13
Business Environment ................................................................................................................6-13
Master Scheduling Process ........................................................................................... 6-19
Introduction ................................................................................................................................ 6-19
Maintaining the Stability of MPS ................................................................................................6-39
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 4.3 vi © 2014 APICS

9. Table of Contents
Participant Workbook Page
Session 7—Managing the Master Schedule
Management Considerations ...........................................................................................7-7
The Balancing Act ..........................................................................................................................7-7
The Role of the Master Scheduler ................................................................................................7-9
The Role of the Senior Executive ................................................................................................ 7-11
Planning and Coordinating Changes… .........................................................................................7-13
Maintaining the Integrity of the Master Schedule .......................................................................7-27
Assemble-to-Order Master Scheduling ............................................................................7-31
Bills of Material ..............................................................................................................................7-31
Planning Bills of Material ..............................................................................................................7-33
Two-Level Master Scheduling Demonstration and Problems .....................................................7-43
Reviewing Capacity Requirements. .................................................................................7-55
Rough-Cut Capacity planning .......................................................................................................7-55
RCCP Process ................................................................................................................................7-57
Possible Solutions .........................................................................................................................7-63
Overload and Underload ...............................................................................................................7-65
Revised MPS and RCCP Report ................................................................................................ 7-67
Advanced Planning and Scheduling (APS) ......................................................................7-69
Approach to Capacity Planning. ................................................................................................ 7-69
APS Process. ................................................................................................................................ 7-71
Measuring Master Scheduling Performance ................................................................ 7-73
Policies and Methods ....................................................................................................................7-73
Problem Indicators. ........................................................................................................................7-75
Performance Measures .................................................................................................................7-77
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
© 2014 APICS vii Instructor Guide Version 4.3

10. Master Planning of Resources
Session 8—Case Studies
Case Studies ................................................................................................................... 8-7
Production Planning Methods .................................................................................................... 8-7
Master Scheduling in a Make-to-Order Environment ............................................................... 8-13
Master Scheduling in a Make-to-Stock Environment ............................................................... 8-19
Appendix
Progress Check Answer Sheet ....................................................................................... A-1
Bibliography .................................................................................................................... A-2
Index
Index ................................................................................................................................ Index 1
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 4.3 viii © 2014 APICS