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Production Plan in Business Plan: A Comprehensive Guide to Success

Last Updated:  

October 22, 2024

In any business venture, a solid production plan is crucial for success. A production plan serves as a roadmap that outlines the steps, resources, and strategies required to manufacture products or deliver services efficiently. By carefully crafting a production plan within a business plan, entrepreneurs can ensure optimal utilisation of resources, timely delivery, cost efficiency, and customer satisfaction. In this article, we will delve into the intricacies of creating an effective production plan in a business plan , exploring its key components, strategies, and the importance of aligning it with overall business objectives .

Key Takeaways on Production Plans in Business Planning

• A production plan : a detailed outline that guides efficient product manufacturing or service delivery.
• Importance of a production plan : provides a roadmap for operations, optimises resource utilisation, and aligns with customer demand.
• Key components : demand forecasting, capacity planning, inventory management, resource allocation, and quality assurance.
• Strategies : lean manufacturing, JIT inventory, automation and technology integration, supplier relationship management, and continuous improvement.
• Benefits of a well-executed production plan : improved efficiency, reduced costs, enhanced product quality, and increased profitability.

What is a Production Plan?

A production Seamless Searches plan is a detailed outline that specifies the processes, resources, timelines, and strategies required to convert raw materials into finished goods or deliver services. It serves as a blueprint for the entire production cycle, guiding decision-making and resource allocation. The production plan considers factors such as demand forecasting, capacity planning, inventory management, and quality assurance to ensure efficient operations and optimal customer satisfaction.

Why is a Production Plan Important in a Business Plan?

The inclusion of a production plan in a business plan is vital for several reasons. First and foremost, it provides a clear roadmap for business operations, helping entrepreneurs and managers make informed decisions related to production processes. A well-developed production plan ensures that resources are utilised efficiently, minimising wastage and optimising productivity. This is particularly important for any startup platform aiming to streamline its production processes and achieve sustainable growth.

Additionally, a production plan allows businesses to align their production capabilities with customer demand. By forecasting market trends and analysing customer needs, businesses can develop a production plan that caters to current and future demands, thus avoiding overstocking or understocking situations. For those interested in property development, understanding the dynamics of the real estate market can provide valuable insights into aligning production capabilities with demand, ensuring successful projects and investments.

Furthermore, a production plan helps businesses enhance their competitive advantage. By implementing strategies such as lean manufacturing and invoice automation , companies can streamline their production processes, reduce costs, improve product quality, and ultimately outperform competitors.

Key Components of a Production Plan

To create an effective production plan, it is crucial to consider several key components. These components work together to ensure efficient operations and successful fulfilment of customer demands. Let's explore each component in detail.

Demand Forecasting

Demand forecasting is a critical aspect of production planning. By analysing historical data, market trends, and customer behaviour, businesses can predict future demand for their products or services. Accurate demand forecasting allows companies to optimise inventory levels, plan production capacity, and ensure timely delivery to customers.

One approach to demand forecasting is quantitative analysis, which involves analysing historical sales data to identify patterns and make predictions. Another approach is qualitative analysis, which incorporates market research, customer surveys, and expert opinions to gauge demand fluctuations. By combining both methods, businesses can develop a robust demand forecast, minimising the risk of underproduction or overproduction. Utilising a free notion template for demand forecasting can further streamline this process, allowing businesses to organise and analyse both quantitative and qualitative data efficiently in one centralised location.

Capacity Planning

Capacity planning involves determining the optimal production capacity required to meet projected demand. This includes assessing the production capabilities of existing resources, such as machinery, equipment, and labour, and identifying any gaps that need to be addressed. By conducting a thorough capacity analysis, businesses can ensure that their production capacity aligns with customer demand, avoiding bottlenecks or excess capacity.

An effective capacity plan takes into account factors such as production cycle times, labour availability, equipment maintenance, and production lead times, which can be supported by supplier portal software .

Inventory Management

Efficient inventory management is crucial for a successful production plan. It involves balancing the cost of holding inventory with the risk of stockouts. By maintaining optimal inventory levels, businesses can reduce carrying costs while ensuring that sufficient stock is available to fulfil customer orders.

Inventory management techniques, such as the Economic Order Quantity (EOQ) model and Just-in-Time (JIT) inventory system, help businesses strike the right balance between inventory investment and customer demand. These methods consider factors such as order frequency, lead time, and carrying costs to optimise inventory levels and minimise the risk of excess or insufficient stock.

Resource Allocation

Resource allocation plays a pivotal role in a production plan. It involves assigning available resources, such as labour, materials, and equipment, to specific production tasks or projects. Effective resource allocation ensures that resources are utilised optimally, avoiding underutilisation or over-utilisation.

To allocate resources efficiently, businesses must consider factors such as skill requirements, resource availability, project timelines, and cost constraints. By conducting a thorough resource analysis and implementing resource allocation strategies, businesses can streamline production processes, minimise bottlenecks, and maximise productivity .

Quality Assurance

Maintaining high-quality standards is essential for any production plan. Quality assurance involves implementing measures to monitor and control the quality of products or services throughout the production process. By adhering to quality standards and conducting regular inspections, businesses can minimise defects, ensure customer satisfaction, and build a positive brand reputation.

Quality assurance techniques, such as Total Quality Management (TQM) and Six Sigma , help businesses identify and rectify any quality-related issues. These methodologies involve continuous monitoring, process improvement, and employee training to enhance product quality and overall operational efficiency.

In addition to the core components of a production plan, it's also important for businesses to consider the broader aspects of their business strategy, including marketing and advertising. Understanding the costs and returns of different marketing approaches is crucial for comprehensive business planning . For instance, direct response advertising costs can vary significantly, but they offer the advantage of measurable responses from potential customers. This type of advertising can be a valuable strategy for businesses looking to directly engage with their target audience and track the effectiveness of their marketing efforts.

Strategies for Developing an Effective Production Plan

Developing an effective production plan requires implementing various strategies and best practices. By incorporating these strategies into the production planning process, businesses can optimise operations and drive success. Let's explore some key strategies in detail.

Lean Manufacturing

Lean manufacturing is a systematic Seamless Searches approach aimed at eliminating waste and improving efficiency in production processes. It emphasises the concept of continuous improvement and focuses on creating value for the customer while minimising non-value-added activities.

By adopting lean manufacturing principles, such as just-in-time production, standardised work processes, and visual management, businesses can streamline operations, reduce lead times, and eliminate unnecessary costs. Lean manufacturing not only improves productivity but also enhances product quality and customer satisfaction.

Just-in-Time (JIT) Inventory

Just-in-Time (JIT) inventory is a strategy that aims to minimise inventory levels by receiving goods or materials just when they are needed for production. This strategy eliminates the need for excess inventory storage, reducing carrying costs and the risk of obsolete inventory.

By implementing a JIT inventory system, businesses can optimise cash flow, reduce storage space requirements, and improve overall supply chain efficiency. However, it requires robust coordination with suppliers, accurate demand forecasting, and efficient logistics management to ensure timely delivery of materials.

Automation and Technology Integration

Automation and technology integration play a crucial role in modern production planning, as well as mobile app development . By leveraging technology, businesses can streamline processes, enhance productivity, and reduce human error. Automation can be implemented in various aspects of production, including material handling, assembly, testing, and quality control.

Continuous Improvement

Continuous improvement is a fundamental principle of effective production planning. It involves regularly evaluating production processes, identifying areas for improvement, and implementing changes to enhance efficiency and quality.

By fostering a culture of continuous improvement, businesses can drive innovation, optimise resource utilisation, and stay ahead of competitors. Techniques such as Kaizen, Six Sigma, and value stream mapping can help businesses identify inefficiencies, eliminate waste, and streamline production workflows.

Frequently Asked Questions (FAQs)

What is the role of a production plan in business planning.

A1: A production plan plays a crucial role in business planning by providing a roadmap for efficient production processes. It helps align production capabilities with customer demand, optimise resource utilisation, and ensure timely delivery of products or services.

How does a production plan affect overall business profitability?

A2: A well-developed production plan can significantly impact business profitability. By optimising production processes, reducing costs, and enhancing product quality, businesses can improve their profit margins and gain a competitive edge in the market.

What are the common challenges faced in production planning?

A3: Production planning can present various challenges, such as inaccurate demand forecasting, capacity constraints, supply chain disruptions, and quality control issues. Overcoming these challenges requires robust planning, effective communication, and the implementation of appropriate strategies and technologies.

What is the difference between short-term and long-term production planning?

A4: Short-term production planning focuses on immediate production requirements, such as daily or weekly schedules. Long-term production planning, on the other hand, involves strategic decisions related to capacity expansion, technology investments, and market expansion, spanning months or even years.

How can a production plan be adjusted to accommodate changes in demand?

A5: To accommodate changes in demand, businesses can adopt flexible production strategies such as agile manufacturing or dynamic scheduling. These approaches allow for quick adjustments to production levels, resource allocation, and inventory management based on fluctuating customer demand.

In conclusion, a well-crafted production plan is essential for business success. By incorporating a production plan into a comprehensive business plan, entrepreneurs can optimise resource utilisation, meet customer demands, enhance product quality, and drive profitability. Through effective demand forecasting, capacity planning, inventory management, resource allocation, and quality assurance, businesses can streamline production processes and gain a competitive edge in the market.

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Production Planning 101: Making a Production Plan (Example Included)

As the creation of products and services has become more extensive and varied, the manufacturing industry has become more competitive. There are many things to keep an eye on such as material requirements planning, supply chain management and inventory control. Operations continue to become more complex, meaning manufacturing companies require more thorough production planning.

A production plan is the best way to guarantee you deliver high-quality products or services as efficiently as possible.

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What Is Production Planning?

Production planning is the process of deciding how a product or service will be manufactured before the manufacturing process begins. In other words, it’s how you plan to manage your supply chain, raw materials, employees and the physical space where the manufacturing process occurs.

Production planning is important for manufacturers as it affects other important aspects of their business such as:

• Supply chain management
• Production scheduling
• Material requirements planning
• Production lead time
• Capacity planning

ProjectManager is project management software that helps manufacturers cover every aspect of production planning. Plan with Gantt charts, execute with kanban boards and manage resources along the way. No other software offers sophisticated project and resource management features in one intuitive package. Get started today for free.

Why Is Production Planning Important?

If a manufacturing operation wishes to expand, that evolution demands careful production planning and scheduling. Someone must take on the responsibility of managing resources and deciding how they’ll be allocated. This process is a big part of capacity planning —how much can be made in a certain period, with the available resources?

Without production planning, it’s easy to use too much of a resource for one product and not leave enough for another, or fail to schedule your resources properly, which results in delays that affect your overall production management process. It’s just as easy to let resources go to waste. These issues indicate a lack of efficiency in your production planning process.

Production planning is the best way to ensure resources are used appropriately, products and services are high-quality and nothing goes over budget . In most organizations, a production manager manages the production planning process.

What Does a Production Planner Do?

A production planner is a team leader who oversees the production planning process, which defines how an organization will approach major areas of production management such as production scheduling, resource capacity planning, production control and production budgeting to manufacture products.

To better understand what a production planner does and the importance of this role in any manufacturing organization, let’s dive into each step of the production planning process.

10 Steps of the Production Planning Process

The production planning process consists of an organization’s actions to make a production strategy that allows it to manufacture products most efficiently and profitably. Here are 10 key steps you should follow when planning your production process.

1. Use Production Forecasting Methods for Estimating Customer Demand

The first step of the production planning process is to forecast the customer demand for your product for a future period like a year or a quarter. To do so, manufacturers rely on quantitative and qualitative techniques such as Delphi method, historical analogy method, moving average method and the analysis of business data and sales forecasts.

This process is known as demand planning , which helps manufacturers be better prepared to meet the demand for their products and manufacture the right quantity so they can minimize production and operational costs.

2. Gauge Your Production Capacity

The term production capacity refers to the maximum quantity of product a manufacturing company can produce based on its available production resources such as raw materials, labor, equipment and machinery.

Once you better understand the customer demand for your product, you’ll need to gauge the total quantity of product that needs to be manufactured and then evaluate if your production capacity is sufficient.

3. Map Out the Shop Floor Layout

Now think about the steps of the production process itself. Outline the production tasks that must be executed to transform raw materials, parts and components into a final product and the physical route that those elements will follow to move across the shop floor. This will allow you to pick a production floor layout that minimizes the time and effort required from your employees.

4. Make a Production Budget to Find the Optimal Production Volume

The next challenge in the production planning process is determining the exact number of units to manufacture to keep up with customer demand and maintain your desired stock levels.

This requires a production budget , a document used to calculate the number of units that should be produced by a company to meet the customer demand for a period such as a month, quarter or even a year.

Creating a production budget involves assessing the current product inventory, the production capacity, sales forecasts and the ending inventory that should remain at the end of the period. Once you analyze these variables and use the production budgeting formula, you’ll know the required production level for a given time.

5. Choose a Production Costing Technique

Choose a costing method for your production process such as activity-based costing, process costing, job costing or simply standard costing. Each has its pros and cons depending on your organization’s particular characteristics.

6. Create a Production Schedule

Now it’s time to make a production schedule that allows your organization to create a stock inventory, deliver products to distribution channels, fulfill customer orders and meet the obligations of any manufacturing contracts the organization has in place for the production timeline you’re planning for.

7. Establish a Production Control System

Next, it’s important to establish standard operating procedures and key performance indicators and use a variety of production control tools to create a system that allows you to track the production process to ensure your products meet quality standards and are manufactured on time and under budget.

8. Set Production Reporting Guidelines

After you’ve decided what KPIs will be used to monitor the efficiency of your production process, you’ll need to determine what types of reports will be used to communicate these metrics with stakeholders and the frequency in which they’ll be produced.

The documentation from each of these production planning stages, such as the production budget and production schedule are gathered in a larger document called the production plan.

What Is a Production Plan?

A production plan is a document that describes how production processes will be executed, and it’s the outcome of the production planning process. It describes the human resources, raw materials and equipment needed and the production schedule that will be followed.

The person responsible for production planning must also be very familiar with the operation’s inner workings, project resources and the products/services they produce. This usually entails collaborating with people on the floor, in the field or in different departments to create products and deliver services.

Production Plan Example

The best way to illustrate this process is through an example. When you set out to create a production plan, make sure to follow these steps to make it as robust as possible.

Sales Forecast

Making a sales forecast greatly helps you decide which product planning method is best for your operation given your production capacity. You’ll need to use diverse sales forecasting techniques to better understand what will be the future demand for your product. From here, you can estimate which resources are required and how they’ll be used in the manufacturing process to begin the production capacity planning process.

Inventory Management Plan

Accessing inventory is about more than simply taking stock: you should make an inventory management plan for your production inventory and work-in-progress inventory so that you don’t experience shortages that might halt production or let things go to waste. For this step, focus on the inventory control and inventory management techniques you can use to handle inventory in the most efficient way possible.

Production Budget

Most manufacturers use the production budgeting formula below to make a production budget that indicates the ideal production volume based on a starting inventory, sales forecasts, production capacity and expected ending inventory levels.

Required Production = Sales Forecast Expected Units + Desired Ending Inventory – Beginning Inventory

Resource Plan

A successful production plan requires you to be familiar with the resource planning details of the manufacturing process, which is why you’ll need to make a resource plan that outlines what resources such as labor, raw materials, equipment and any other capital assets are available for production and when they’re scheduled to be utilized.

Production Cost Estimate

Once you’ve determined what the required level of production is and the resources that will be needed, you’ll need to estimate the cost of production . It’s important to ensure the production process will be profitable before creating a production schedule.

Production Schedule

As stated above, a production schedule is key to making sure your manufacturing team delivers products on time, but also guides efforts in other areas such as supply chain management and logistics management.

Production Control Plan

A production control plan should describe all the metrics, procedures, guidelines and tools that will be utilized to monitor how the results compare to the production schedule and resource management projections. This is something that should continually take place and be documented during the production process.

Types of Production Planning

Every operation is unique, and the same production plan isn’t right for everyone. To get the most from project planning, you decide which method is best for your manufacturing process. Here’s a quick intro to the different types of production planning.

The job method is often used when manufacturing a single product, for which a unique production plan is created. This production planning method is generally used in smaller-scale productions, but it can also be applied to larger manufacturing facilities. The job method is especially advantageous when a production order requires specific customizations.

Batch Production Method

Batch production consists of manufacturing goods in groups, instead of being produced individually or through continuous production . This method is useful when manufacturing products on a large scale.

Flow Method

The flow method is a demand-based manufacturing model that minimizes the production lead time by speeding up the production line. The manufacturing process starts based on work orders, and once it starts, it doesn’t stop until all finished goods are produced. This is called continuous production and it’s achieved by using machinery and little intervention to minimize waiting time.

Process Method

The process method is more or less what most people picture when they think about production—an assembly line . With the process method, there will generally be different types of machinery that complete separate tasks to put together the finished goods.

Mass Production Method

The mass production method primarily focuses on creating a continuous flow of identical products. It’s similar to the flow method, but at a much bigger scale, which cuts production costs. When uniformity is just as critical as efficiency, use “standardized processes” to guarantee all products look the same.

Production Planning Best Practices

No matter what product or service is being manufactured, there are many tried-and-true best practices to increase your operational efficiency . When creating a production plan, keep these two in mind.

Make Accurate Forecasts

When you don’t properly estimate the demand for your product or service, it’s impossible to create a detailed production plan. Demand planning is never static. Consider buying trends from previous years, changes in demographics, changes in resource availability and many other factors. These demand planning forecasts are the foundation of skillful production planning.

Know Your Capacity

Capacity planning means knowing the maximum capacity your operation can manage—the absolute most of a product or service it can offer during a period of time. This is the only way to anticipate how much of each resource you need to create X amount of products.

When you don’t know the production capacity, your production planning is like taking a shot in the dark.

Common Production Planning Mistakes

Stay vigilant of common missteps as you go through the production planning process. Here are three mistakes often made during production planning. Luckily, they can be prevented.

Not Expecting the Unexpected

This means having risk management strategies in place if things go awry. The goal is to never have to employ them, of course, but it’s better to have them and not need them. Production planning is incomplete if it doesn’t anticipate risks, issues and changes. When you plan for them, you’re ready to problem-solve if and when they happen.

Getting Stuck Behind the Desk

You should work with intelligent production planning tools, but that doesn’t mean you should only rely on enterprise resource planning software for production planning and not oversee resources and manufacturing operations in person. When production planning is only done from behind a screen, the result won’t be as informed as it could be. The best production planning is active and collaborative.

Neglecting Equipment

To get the most from your equipment, you need to take care of it. This means tracking usage and keeping up with regular maintenance. This looks different depending on the industry and product or service, but the principle is the same: continually take care of your equipment before it becomes a problem that slows down production.

Use ProjectManager for Production Planning and Scheduling

As the nature of manufacturing goods and services changes, you need modern tools to plan production and make schedules. ProjectManager is award-winning project management software that offers all the tools you need for excellent production planning and scheduling. With it, you can plan projects, create schedules, manage resources and track changes with one tool.

Plan With Gantt Charts

Manage your product manufacturing across a timeline with our Gantt chart view. With it, you can view your resources to help you track your cost of production to ensure you’re never overspending. You can then link any dependent tasks to avoid bottlenecks in your manufacturing.

Get a Bird’s-Eye View

To keep your production plan on track, you need a high-level view to pinpoint setbacks before or as they occur. Our real-time dashboard collects data and converts it into colorful graphs and charts that give you at-a-glance analytics.

Easily Measure and Report Your Progress

Any operation will have stakeholders who want to be kept in the loop. ProjectManager’s project status reports make it easy to share key data points. They can be generated in a single click, making it simple to generate them before important meetings.

Related Production Planning Content

The production planning process involves many different activities such as estimating the quantity of goods to be produced, the resources needed, the production schedule and much more. That’s why we’ve created dozens of blogs, guides and templates on production management topics. Here are some of them.

• Production vs. Manufacturing
• How to Make a Production Flow Chart for Manufacturing
• Best Production Scheduling Software Rankings
• How to Create a Master Production Schedule (MPS)

Manage every detail of your operation with ProjectManager’s powerful online project management tools. Our suite of tools is trusted by tens of thousands of teams, from NASA to Volvo, to aid them in the planning, scheduling, tracking and reporting on the progress and performance of their production plans. Our software lets you get out from behind your desk and make adjustments on the go. Try it for yourself for free for 30 days!

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How to Write the Operations Plan Section of a Business Plan

Susan Ward wrote about small businesses for The Balance for 18 years. She has run an IT consulting firm and designed and presented courses on how to promote small businesses.

How to Write the Operations Plan Section of the Business Plan

Stage of development section, production process section, the bottom line, frequently asked questions (faqs).

The operations plan is the section of your business plan that gives an overview of your workflow, supply chains, and similar aspects of your business. Any key details of how your business physically produces goods or services will be included in this section.

You need an operations plan to help others understand how you'll deliver on your promise to turn a profit. Keep reading to learn what to include in your operations plan.

Key Takeaways

• The operations plan section should include general operational details that help investors understand the physical details of your vision.
• Details in the operations plan include information about any physical plants, equipment, assets, and more.
• The operations plan can also serve as a checklist for startups; it includes a list of everything that must be done to start turning a profit.

In your business plan , the operations plan section describes the physical necessities of your business's operation, such as your physical location, facilities, and equipment. Depending on what kind of business you'll be operating, it may also include information about inventory requirements, suppliers, and a description of the manufacturing process.

Staying focused on the bottom line will help you organize this part of the business plan.

Think of the operating plan as an outline of the capital and expense requirements your business will need to operate from day to day.

You need to do two things for the reader of your business plan in the operations section: show what you've done so far to get your business off the ground and demonstrate that you understand the manufacturing or delivery process of producing your product or service.

When you're writing this section of the operations plan, start by explaining what you've done to date to get the business operational, then follow up with an explanation of what still needs to be done. The following should be included:

Production Workflow

A high-level, step-by-step description of how your product or service will be made, identifying the problems that may occur in the production process. Follow this with a subsection titled "Risks," which outlines the potential problems that may interfere with the production process and what you're going to do to negate these risks. If any part of the production process can expose employees to hazards, describe how employees will be trained in dealing with safety issues. If hazardous materials will be used, describe how these will be safely stored, handled, and discarded.

Industry Association Memberships

Show your awareness of your industry's local, regional, or national standards and regulations by telling which industry organizations you are already a member of and which ones you plan to join. This is also an opportunity to outline what steps you've taken to comply with the laws and regulations that apply to your industry. 

Supply Chains

An explanation of who your suppliers are and their prices, terms, and conditions. Describe what alternative arrangements you have made or will make if these suppliers let you down.

Quality Control

An explanation of the quality control measures that you've set up or are going to establish. For example, if you intend to pursue some form of quality control certification such as ISO 9000, describe how you will accomplish this.

While you can think of the stage of the development part of the operations plan as an overview, the production process section lays out the details of your business's day-to-day operations. Remember, your goal for writing this business plan section is to demonstrate your understanding of your product or service's manufacturing or delivery process.

When writing this section, you can use the headings below as subheadings and then provide the details in paragraph format. Leave out any topic that does not apply to your particular business.

Do an outline of your business's day-to-day operations, including your hours of operation and the days the business will be open. If the business is seasonal, be sure to say so.

The Physical Plant

Describe the type, size, and location of premises for your business. If applicable, include drawings of the building, copies of lease agreements, and recent real estate appraisals. You need to show how much the land or buildings required for your business operations are worth and tell why they're important to your proposed business.

The same goes for equipment. Besides describing the equipment necessary and how much of it you need, you also need to include its worth and cost and explain any financing arrangements.

Make a list of your assets , such as land, buildings, inventory, furniture, equipment, and vehicles. Include legal descriptions and the worth of each asset.

Special Requirements

If your business has any special requirements, such as water or power needs, ventilation, drainage, etc., provide the details in your operating plan, as well as what you've done to secure the necessary permissions.

State where you're going to get the materials you need to produce your product or service and explain what terms you've negotiated with suppliers.

Explain how long it takes to produce a unit and when you'll be able to start producing your product or service. Include factors that may affect the time frame of production and describe how you'll deal with potential challenges such as rush orders.

Explain how you'll keep  track of inventory .

Feasibility

Describe any product testing, price testing, or prototype testing that you've done on your product or service.

Give details of product cost estimates.

Once you've worked through this business plan section, you'll not only have a detailed operations plan to show your readers, but you'll also have a convenient list of what needs to be done next to make your business a reality. Writing this document gives you a chance to crystallize your business ideas into a clear checklist that you can reference. As you check items off the list, use it to explain your vision to investors, partners, and others within your organization.

What is an operations plan?

An operations plan is one section of a company's business plan. This section conveys the physical requirements for your business's operations, including supply chains, workflow , and quality control processes.

What is the main difference between the operations plan and the financial plan?

The operations plan and financial plan tackle similar issues, in that they seek to explain how the business will turn a profit. The operations plan approaches this issue from a physical perspective, such as property, routes, and locations. The financial plan explains how revenue and expenses will ultimately lead to the business's success.

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What is Production Planning? Process & Strategies

In the realm of manufacturing and operations management, production planning plays a crucial role in ensuring efficiency, cost-effectiveness, and timely delivery of products. Whether you're producing cars, electronics, or consumer goods, effective production planning can make or break your business's success.

Table of Contents

Understanding production planning, strategies for effective production planning, the production planning process in action, benefits of effective production planning.

Production planning is the process of organizing and coordinating resources, both human and capital, in order to meet the demands of production while maintaining efficiency. It involves forecasting demand, designing a production process, scheduling workloads, and ensuring raw materials and resources are available when needed.

Key Elements of Production Planning

To grasp the intricacies of production planning, it's essential to delve into its core components:

Demand Forecasting: Before embarking on production, businesses must forecast demand accurately. This involves analyzing historical data, market trends, and customer behavior to predict future demand patterns.

Designing the Production Process: Once demand is estimated, the production process must be designed. This includes determining the sequence of operations, selecting appropriate machinery and equipment, and setting up workstations.

Production Scheduling: Scheduling ensures that production activities are coordinated in a timely manner. It involves assigning tasks, allocating resources, and establishing timelines to meet production goals.

Inventory Management: Efficient inventory management is crucial to production planning. It entails maintaining optimal levels of raw materials, work-in-progress (WIP), and finished goods to prevent stockouts or overstock situations.

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Effective production planning involves implementing strategies that streamline processes, reduce waste, and enhance overall productivity. Here are some detailed strategies.

1. Lean Manufacturing Principles

Lean manufacturing is a systematic approach aimed at minimizing waste while maximizing productivity. It focuses on creating more value for customers with fewer resources through continuous improvement and waste reduction techniques.

Key Techniques:

Just-In-Time (JIT) Inventory: JIT aims to minimize inventory holding costs by delivering materials and components just when they are needed for production.

Kaizen (Continuous Improvement): Encourages incremental improvements in processes, products, and services to enhance efficiency and quality continuously.

Benefits: Lean principles reduce lead times, improve product quality, lower production costs, and increase overall responsiveness to customer demands.

2. Capacity Planning

Capacity planning involves determining the production capacity needed to meet current and future demands efficiently. It ensures that resources such as machinery, labor, and workspace are utilized optimally without underutilization or overutilization.

Key Aspects:

Demand Forecasting: Accurately forecast demand to align production capacity accordingly.

Resource Allocation: Allocate resources based on forecasted demand and production schedules.

Scenario Planning: Prepare for different demand scenarios to adjust capacity accordingly.

Benefits: Effective capacity planning prevents production bottlenecks, reduces lead times, improves delivery reliability, and enhances resource utilization.

3. Production Control

Production control encompasses monitoring and regulating production processes to ensure they adhere to planned schedules and quality standards. It involves real-time adjustments to optimize workflow and minimize deviations from production plans.

Key Components:

Real-Time Monitoring: Monitor production processes to identify and resolve issues promptly.

Quality Assurance: Implement quality control measures to maintain consistent product quality.

Schedule Adherence: Ensure that production activities are executed as per the schedule to meet deadlines.

Benefits: Production control enhances efficiency, reduces production downtime, improves on-time delivery performance, and boosts overall operational transparency.

4. Supply Chain Management Integration

Integrating supply chain management (SCM) with production planning ensures seamless coordination from raw material suppliers to end customers. It focuses on optimizing the flow of materials, information, and finances across the supply chain network.

Key Practices:

Supplier Collaboration: Collaborate closely with suppliers to ensure timely delivery of quality materials.

Inventory Optimization: Maintain optimal inventory levels to prevent stockouts or overstock situations.

Logistics Efficiency: Streamline transportation and distribution channels to minimize lead times.

Benefits: SCM integration enhances supply chain responsiveness, reduces costs associated with inventory and transportation, improves product availability, and strengthens supplier relationships.

5. Technology Adoption

Technological advancements play a pivotal role in modern production planning by enabling automation, data-driven decision-making, and real-time visibility into production processes.

Key Technologies:

Enterprise Resource Planning (ERP) Systems: Integrate various aspects of production planning, inventory management, and resource allocation into a unified platform.

Advanced Analytics: Utilize predictive analytics and machine learning algorithms to improve demand forecasting accuracy.

IoT and Automation: Implement IoT devices for real-time monitoring of machinery performance and automated production processes.

Benefits: Technology adoption improves operational efficiency, reduces production costs, enhances decision-making capabilities, and facilitates scalability.

Effective production planning involves a series of systematic steps to ensure that manufacturing operations run smoothly, efficiently, and meet the demands of customers. 

Step 1: Demand Forecasting

Demand forecasting is the initial phase of production planning and involves predicting future demand for products based on historical data, market trends, and customer insights. This step is crucial as it sets the foundation for all subsequent planning activities.

Data Analysis: Production planners analyze historical sales data, customer orders, and market trends to identify patterns and fluctuations in demand.

Market Research: Conducting market research helps gather insights into customer preferences, competitor activities, and economic factors that could impact demand.

Collaboration: Close collaboration between sales teams, marketing, and production planners ensures that demand forecasts are realistic and aligned with business objectives.

Step 2: Resource Allocation

Once demand forecasts are established, the next step is to allocate resources efficiently to meet production requirements while minimizing costs and maximizing productivity.

Material Requirements Planning (MRP): Production planners use MRP systems to calculate the quantity of raw materials needed based on production schedules and inventory levels.

Labor Scheduling: Human resources are allocated based on production volumes, skill requirements, and shift patterns to ensure adequate workforce availability.

Equipment and Facility Planning: Planning includes scheduling equipment usage, maintenance schedules, and ensuring that production facilities are optimized for efficiency.

Step 3: Production Scheduling

Production scheduling involves creating a detailed timeline and sequence of operations for each production order to ensure that products are manufactured on time and according to specifications.

Work Order Creation: Each production order is translated into a work order specifying tasks, quantities, and timelines for completion.

Capacity Planning: Production planners assess the capacity of machines, workstations, and personnel to determine realistic production schedules and avoid overloading resources.

Sequence of Operations: The order in which tasks are performed is determined to minimize setup times, optimize workflow, and maximize throughput.

Step 4: Monitoring and Adjustments

Throughout the production process, continuous monitoring and control are essential to ensure that operations are running according to plan and to address any deviations promptly.

Real-Time Monitoring: Production managers use real-time data from sensors, production reports, and ERP systems to monitor progress, identify bottlenecks, and track key performance indicators (KPIs).

Quality Control: Quality assurance processes are integrated into production workflows to ensure that products meet quality standards and specifications.

Problem Solving: Production planners and managers collaborate to resolve issues such as equipment breakdowns, material shortages, or unexpected changes in demand.

Cost Efficiency

One of the primary advantages of effective production planning is its ability to enhance cost efficiency across the manufacturing process. By accurately forecasting demand and scheduling production accordingly, businesses can optimize resource utilization. This optimization includes minimizing wastage of raw materials, reducing overtime costs by efficient scheduling of labor, and optimizing machine usage to lower energy consumption. Additionally, streamlined processes and reduced lead times contribute to overall cost savings, making operations more financially sustainable.

Improved Productivity

Efficient production planning leads to improved productivity throughout the manufacturing cycle. By carefully allocating resources and scheduling tasks, companies can eliminate bottlenecks and downtime. This ensures that production lines operate smoothly and at maximum capacity, reducing idle time between processes. Moreover, clear timelines and well-defined workflows enhance employee productivity by providing clarity on tasks and expectations. As a result, businesses can produce more output with the same or fewer resources, boosting overall efficiency.

Enhanced Quality Control

Quality control is integral to effective production planning. By adhering to predetermined schedules and processes, businesses can implement rigorous quality checks at each stage of production. This proactive approach helps identify and rectify defects or inconsistencies early on, minimizing the likelihood of product recalls or customer dissatisfaction. Consistent product quality not only enhances customer satisfaction but also strengthens the brand reputation in the market.

Customer Satisfaction

Meeting customer demands in terms of product availability and delivery timelines is crucial for maintaining customer satisfaction. Effective production planning ensures that products are manufactured and delivered on time, meeting market demand without delays. This reliability builds trust with customers and encourages repeat business. Additionally, businesses can respond swiftly to changes in customer preferences or market trends by adjusting production schedules and priorities accordingly, thereby staying competitive in the marketplace.

Optimized Inventory Management

Proper production planning helps in maintaining optimal inventory levels throughout the supply chain. By accurately forecasting demand and scheduling production cycles, businesses can prevent overstocking or stockouts of raw materials, work-in-progress (WIP), and finished goods. This not only reduces holding costs associated with excess inventory but also ensures that products are available when needed, minimizing lead times and improving overall supply chain efficiency.

Strategic Resource Allocation

Effective production planning involves strategic allocation of resources such as manpower, equipment, and facilities. By aligning production schedules with resource availability, businesses can maximize the utilization of existing assets. This includes optimizing machine uptime, reducing setup times between production runs, and balancing workload across shifts or departments. Such strategic resource management not only improves operational efficiency but also supports long-term capacity planning and business growth.

Flexibility and Adaptability

In today's dynamic market environment, businesses must be agile and responsive to changes in customer demand or market conditions. Effective production planning facilitates agility by enabling quick adjustments to production schedules and priorities. This flexibility allows businesses to accommodate rush orders, handle seasonal fluctuations in demand, or respond to unexpected disruptions in the supply chain. By being adaptable, companies can maintain competitiveness and seize opportunities in the marketplace.

In conclusion, production planning is the backbone of manufacturing operations, integrating forecasting, scheduling, and resource management to optimize efficiency and meet customer demands effectively. By adopting advanced strategies like lean manufacturing and leveraging technology for real-time monitoring, businesses can stay competitive in today's dynamic market landscape.

-  What role does technology play in modern production planning?

Technology facilitates real-time monitoring, data analysis for accurate forecasting, and automation of routine tasks, enhancing overall efficiency.

-  How can small businesses benefit from production planning?

Small businesses can optimize resource utilization, reduce costs, and improve customer satisfaction by implementing tailored production planning strategies.

-  What are the common challenges in production planning?

Challenges include demand volatility, supply chain disruptions, balancing production capacity, and maintaining flexibility in operations.

-  How does production planning contribute to sustainability?

Efficient planning minimizes waste generation, conserves resources, and supports sustainable manufacturing practices.

-  What are the key performance indicators (KPIs) for measuring production planning success?

KPIs include on-time delivery rates, capacity utilization, inventory turnover, and adherence to production schedules.

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How to Write a Production Plan for a Business?

A production plan is a critical component of any business that involves manufacturing, construction, or other forms of production. It outlines how a company will produce its goods or services, and it provides a roadmap for success. In this article, we’ll take a look at how to write a production plan for your business.

1. Understand Your Product

The first step in creating a production plan is to understand your product. What are you producing? What are its components? How is it made? Answering these questions will help you determine what resources you need, how long it will take to produce, and how you will produce it.

Before creating a production plan, make sure you have a clear understanding of what you are producing. This will help you make informed decisions about the production process and ensure that you are using the right resources.

2. Determine Your Production Capacity

Once you understand your product, you need to determine your production capacity. How much of your product can you produce in a given period? This will depend on the resources you have available, such as equipment, personnel, and materials.

To determine your production capacity, you should consider the following factors:

– The capacity of your equipment – The availability of raw materials – The number of personnel available – The amount of time required to produce each unit

By understanding your production capacity, you can create a production plan that is realistic and achievable.

3. Create a Production Schedule

With a clear understanding of your product and production capacity, you can create a production schedule. This schedule should outline when you will produce each unit of your product, as well as the resources required to produce it.

When creating a production schedule, you should consider the following factors:

– The production capacity of your equipment – The availability of raw materials – The number of personnel available – The amount of time required to produce each unit – The demand for your product

By creating a production schedule, you can ensure that you are using your resources effectively and efficiently.

4. Determine Your Material Requirements

To produce your product, you will need to determine your material requirements. This includes the raw materials needed to produce each unit, as well as any additional materials required for packaging or shipping.

When determining your material requirements, you should consider the following factors:

– The number of units you plan to produce – The amount of raw materials required for each unit – The cost of the raw materials – The availability of the raw materials

By understanding your material requirements, you can ensure that you have the resources you need to produce your product.

5. Develop a Quality Control Plan

Quality control is an essential component of any production plan. It ensures that your product meets the standards set by your company and your customers.

When developing a quality control plan, you should consider the following factors:

– The standards set by your company and your customers – The methods you will use to ensure quality – The personnel responsible for quality control – The equipment required for quality control

By developing a quality control plan, you can ensure that your product meets the highest standards of quality.

6. Determine Your Personnel Needs

To produce your product, you will need personnel with the right skills and experience. When determining your personnel needs, you should consider the following factors:

– The number of personnel required – The skills and experience required – The cost of personnel – The availability of personnel

By understanding your personnel needs, you can ensure that you have the right people in place to produce your product.

7. Develop a Maintenance Plan

Equipment maintenance is an essential component of any production plan. It ensures that your equipment is in good working order and reduces the risk of breakdowns.

When developing a maintenance plan, you should consider the following factors:

– The frequency of maintenance – The personnel responsible for maintenance – The cost of maintenance – The equipment required for maintenance

By developing a maintenance plan, you can ensure that your equipment is always in good working order.

8. Determine Your Cost of Production

To determine the profitability of your product, you need to determine your cost of production. This includes the cost of raw materials, personnel, equipment, and any other expenses associated with production.

When determining your cost of production, you should consider the following factors:

– The cost of raw materials – The cost of personnel – The cost of equipment – The cost of maintenance – The cost of overhead

By understanding your cost of production, you can ensure that your product is profitable.

9. Monitor and Adjust Your Production Plan

Once you have created your production plan, you need to monitor its effectiveness. This involves tracking your production output, monitoring your costs, and making adjustments as needed.

When monitoring and adjusting your production plan, you should consider the following factors:

– Production output – Cost of production – Quality control results – Equipment maintenance issues

By monitoring and adjusting your production plan, you can ensure that your product is produced efficiently and effectively.

10. Benefits of a Production Plan

A production plan offers several benefits to your business, including:

– Increased efficiency – Improved quality control – Reduced costs – Increased profitability – Better resource management

By creating a production plan, you can ensure that your business is producing its products or services in the most efficient and effective way possible.

Frequently Asked Questions

Here are some common questions and answers about writing a production plan for a business:

What is a production plan?

A production plan is a document that outlines the steps a business will take to manufacture or produce a product. It includes details about the materials needed, the timeline for production, and the resources required to complete the project. A production plan is essential for ensuring that a business can efficiently and effectively produce goods.

When writing a production plan, it’s important to consider factors like the demand for your product, the availability of resources, and the complexity of the manufacturing process. By taking these factors into account, you can create a plan that will help your business succeed.

What should be included in a production plan?

A production plan should include a detailed timeline for production, a list of the materials needed for manufacturing, and information about the resources required to complete the project. It should also outline the steps involved in the manufacturing process and any quality control measures that will be used to ensure that the final product meets the necessary standards.

Additionally, a production plan should include information about the expected demand for the product, as well as any potential challenges that may arise during production. By including these details in your plan, you can ensure that your business is prepared to meet the needs of your customers and overcome any obstacles that may arise.

What are the benefits of a production plan?

Having a production plan in place can provide several benefits for a business. For one, it can help ensure that the manufacturing process is efficient and cost-effective, as it allows you to identify any potential issues and address them before they become major problems. Additionally, a production plan can help you manage your resources more effectively, as it provides a clear timeline for production and ensures that you have the necessary materials and personnel in place to complete the project.

Finally, a production plan can help you stay on track and meet your deadlines, which is essential for maintaining a positive reputation with your customers and stakeholders. By creating a detailed plan and sticking to it, you can ensure that your business is able to deliver high-quality products on time and within budget.

How can I create a production plan?

To create a production plan, start by identifying the materials and resources you will need to manufacture your product. Then, create a detailed timeline for production that includes key milestones and deadlines. Be sure to consider factors like the complexity of the manufacturing process, the availability of resources, and the expected demand for your product.

Once you have a basic plan in place, review it carefully to identify any potential issues or challenges. Make adjustments as needed to ensure that your plan is realistic and achievable. Finally, communicate your plan clearly to your team and stakeholders to ensure that everyone is on the same page and working towards the same goals.

How often should I update my production plan?

It’s important to review and update your production plan regularly to ensure that it remains relevant and effective. Depending on the nature of your business and the products you produce, you may need to update your plan on a monthly, quarterly, or annual basis.

When updating your plan, be sure to consider any changes in demand, resources, or production processes that may have occurred since the last update. This will help you ensure that your plan remains accurate and effective, and that your business is able to meet the needs of your customers and stakeholders.

Production Plan

To create a successful production plan, start by identifying your goals and objectives. Consider factors such as customer demand, production capacity, and available resources. From there, break down your plan into manageable steps, and set realistic timelines for each stage of production.

Lastly, remember that your production plan is not set in stone. As your business grows and evolves, your production plan will need to evolve with it. Be prepared to make changes and adjustments to your plan as needed, and don’t be afraid to seek out help and advice from experts in the field. With the right approach and a solid plan in place, you can take your business to the next level and achieve lasting success.

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Operations Plan

• Lesson Materials Operations Plan Worksheet
• Completion time About 40 minutes

The operations section of your business plan is where you explain – in detail – you company's objectives, goals, procedures, and timeline. An operations plan is helpful for investors, but it's also helpful for you and employees because it pushes you to think about tactics and deadlines.

In the previous course, you outlined your company's strategic plan, which answers questions about your business mission. An operational plan outlines the steps you'll take to complete your business mission.

Your operations plan should be able to answer the following:

• Who – The personnel or departments who are in charge of completing specific tasks.
• What – A description of what each department is responsible for.
• Where – The information on where daily operations will be taking place.
• When –The deadlines for when the tasks and goals are to be completed.
• How much – The cost amount each department needs to complete their tasks.

In this session, we explain each item to include in your operations plan.

Goals and Objectives

The key to an operations plan is having a clear objective and goal everyone is focused on completing. In this section of your plan, you'll clearly state what your company's operational objective is.

Your operational objective is different than your company's overall objective. In Course One , you fleshed out what your strategic objective was. Your operational objective explains how you intend to complete your strategic objective.

In order to create an efficient operational objective, think SMART:

• Specific – Be clear on what you want employees to achieve.
• Measurable – Be able to quantify the goal in order to track progress.
• Attainable & Realistic – It's great to be ambitious but make sure you aren't setting your team up for failure. Create a goal that everyone is motivated to complete with the resources available.
• Timely – Provide a deadline so everyone has a date they are working towards.

Different departments will have different operational objectives. However, each department objective should help the company reach the main objective. In addition, operational objectives change; the objectives aren't intended to be permanents or long term. The timeline should be scheduled with your company's long-term goals in mind.

Let's look at the following example for a local pizza business objective:

• Strategic objective : To deliver pizza all over Eastern Massachusetts.
• Technology department operational objective : To create a mobile app by January 2017 to offer a better user experience.
• Marketing department operational objective : To increase website visitors by 50% by January 2017 by advertising on radio, top local food websites, and print ads.
• Sales department operational objective : To increase delivery sales by 30%, by targeting 3 of Massachusetts's largest counties.

Sales department operational objective: To increase delivery sales by 30%, by targeting 3 of Massachusetts's largest counties.

Production Process

After you create your objectives, you have to think strategically on how you're going to meet them. In order to do this, each department (or team) needs to have all the necessary resources for the production process.

Resources you should think about include the following:

• Suppliers – do you have a supplier (or more) to help you produce your product?
• Technology team: app developing software
• Marketing team: software licenses for website analytical tools
• Sales team: headsets, phone systems or virtual phone system technology
• Cost – what is the budget for each department?

In addition to the production process, you'll also need to describe in detail your operating process. This will demonstrate to investors that you know exactly how you want your business to run on a day-to-day basis.

Items to address include:

• Location – where are employees working? Will you need additional facilities?
• Work hours – will employees have a set schedule or flexible work schedule?
• Personnel – who is in charge of making sure department tasks are completed?

Creating a timeline with milestones is important for your new business. It keeps everyone focused and is a good tracking method for efficiency. For instance, if milestones aren’t being met, you'll know that it's time to re-evaluate your production process or consider new hires.

Below are common milestones new businesses should plan for.

When you completed your Management Plan Worksheet in the previous course, you jotted down which key hires you needed right away and which could wait. Make sure you have a good idea on when you would like those key hires to happen; whether it’s after your company hits a certain revenue amount or once a certain project takes off.

Production Milestones

Production milestones keep business on track. These milestones act as "checkpoints" for your overall department objectives. For instance, if you want to create a new app by the end of the year, product milestones you outline might include a beta roll out, testing, and various version releases.

Other product milestones to keep in mind:

• Design phase
• Product prototype phase
• Product launch
• Version release

Market Milestones

Market milestones are important for tracking efficiency and understanding whether your operations plan is working. For instance, a possible market milestone could be reaching a certain amount of clients or customers after a new product or service is released.

A few other market milestones to consider:

• Gain a certain amount of users/clients by a certain time
• Signing partnerships
• Running a competitive analysis
• Performing a price change evaluation

Financial Milestones

Financial milestones are important for tracking business performance. It's likely that a board of directors or investors will work with you on creating financial milestones. In addition, in startups, it's common that financial milestones are calculated for 12 months.

Typical financial milestones include:

• Funding events
• Revenue and profit goals
• Transaction goals

In summary, your operations plan gives you the chance to show investors you know how you want your business to run. You know who you want to hire, where you want to work, and when you expect projects to be completed.

Download the attached worksheet and start putting your timelines and milestones together on paper.

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10.3: The Production Process- How Do We Make It?

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2. What types of production processes do manufacturers and service firms use?

In production planning, the first decision involves which type of production process —the way a good or service is created—best fits with company goals and customer demand. An important consideration is the type of good or service being produced, because different goods may require different production processes. In general, there are three types of production: mass production, mass customization, and customization. In addition to production type, operations managers also classify production processes in two ways: (1) how inputs are converted into outputs and (2) the timing of the process.

One for All: Mass Production

Mass production , manufacturing many identical goods at once, was a product of the Industrial Revolution. Henry Ford’s Model-T automobile is a good example of early mass production. Each car turned out by Ford’s factory was identical, right down to its color. If you wanted a car in any color except black, you were out of luck. Canned goods, over-the-counter drugs, and household appliances are other examples of goods that are mass-produced. The emphasis in mass production is on keeping manufacturing costs low by producing uniform products using repetitive and standardized processes. As products became more complicated to produce, mass production also became more complex. Automobile manufacturers, for example, must now incorporate more sophisticated electronics into their car designs. As a result, the number of assembly stations in most automobile manufacturing plants has increased.

Just for You: Customizing Goods

In mass customization , goods are produced using mass-production techniques, but only up to a point. At that point, the product or service is custom-tailored to the needs or desires of individual customers. For example, American Leather, a Dallas-based furniture manufacturer, uses mass customization to produce couches and chairs to customer specifications within 30 days. The basic frames in the furniture are the same, but automated cutting machinery precuts the color and type of leather ordered by each customer. Using mass-production techniques, they are then added to each frame.

Customization is the opposite of mass production. In customization, the firm produces goods or services one at a time according to the specific needs or wants of individual customers. Unlike mass customization, each product or service produced is unique. For example, a print shop may handle a variety of projects, including newsletters, brochures, stationery, and reports. Each print job varies in quantity, type of printing process, binding, color of ink, and type of paper. A manufacturing firm that produces goods in response to customer orders is called a job shop .

Some types of service businesses also deliver customized services. Doctors, for instance, must consider the illnesses and circumstances of each individual patient before developing a customized treatment plan. Real estate agents may develop a customized service plan for each customer based on the type of house the person is selling or wants to buy. The differences between mass production, mass customization, and customization are summarized in Exhibit 10.5 .

Converting Inputs to Outputs

As previously stated, production involves converting inputs (natural resources, raw materials, human resources, capital) into outputs (products or services). In a manufacturing company, the inputs, the production process, and the final outputs are usually obvious. Harley-Davidson, for instance, converts steel, rubber, paint, and other inputs into motorcycles. But the production process in a service company involves a less obvious conversion. For example, a hospital converts the knowledge and skills of its medical personnel, along with equipment and supplies from a variety of sources, into health care services for patients. Table 10.1 provides examples of the inputs and outputs used by various other businesses.

There are two basic processes for converting inputs into outputs. In process manufacturing , the basic inputs (natural resources, raw materials) are broken down into one or more outputs (products). For instance, bauxite (the input) is processed to extract aluminum (the output). The assembly process is just the opposite. The basic inputs, like natural resources, raw materials, or human resources, are either combined to create the output or transformed into the output. An airplane, for example, is created by assembling thousands of parts, which are its raw material inputs. Steel manufacturers use heat to transform iron and other materials into steel. In services, customers may play a role in the transformation process. For example, a tax preparation service combines the knowledge of the tax preparer with the client’s information about personal finances in order to complete the tax return.

Production Timing

A second consideration in choosing a production process is timing. A continuous process uses long production runs that may last days, weeks, or months without equipment shutdowns. This is best for high-volume, low-variety products with standardized parts, such as nails, glass, and paper. Some services also use a continuous process. Your local electric company is an example. Per-unit costs are low, and production is easy to schedule.

In an intermittent process , short production runs are used to make batches of different products. Machines are shut down to change them to make different products at different times. This process is best for low-volume, high-variety products such as those produced by mass customization or customization. Job shops are examples of firms using an intermittent process.

Although some service companies use continuous processes, most service firms rely on intermittent processes. For instance, a restaurant preparing gourmet meals, a physician performing surgical procedures, and an advertising agency developing ad campaigns for business clients all customize their services to suit each customer. They use the intermittent process. Note that their “production runs” may be very short—one grilled salmon or one physical exam at a time.

CONCEPT CHECK

• Describe the different types of production processes.
• How are inputs transformed into outputs in a variety of industries?

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How to Write an Operations Plan Section of your Business Plan

Free Operations Plan Template

• June 26, 2024

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An operational plan bridges the gap between high ambitions and actual achievements. This essential integral section helps businesses thrive, achieve their goals, and handle challenges with accuracy and purpose.

But is it challenging for you to write one in a manner that shows a clear picture of your business operations? Drafting the operations plan section can be tricky due to the uncertainties of the business environment and the risks associated with it.

Well, worry not you’re at the right place! Here, we will see how to write an engaging operational plan in a business plan with an example. So let’s get going.

What is an operations plan?

An operations plan of a business plan is an in-depth description of your daily business activities centered on achieving the goals and objectives described in the previous sections of the plan. It outlines various departments’ processes, activities, responsibilities, and execution time frame.

The operations section explains in detail the role of a team or department in the collective accomplishment of your goals. In other words, it’s a strategic allocation of physical, financial, and human resources toward reaching milestones within a specific timeframe.

Key questions your operational plan should address

A successful operational plan section of your business plan should be able to answer the following questions:

• Who is responsible for a specific task or department?
• What are the tasks that need to be completed?
• Where will these operations take place?
• When should the tasks be completed? What are the deadlines?
• How will the tasks be performed? Is there a standard procedure?
• How much is it going to cost to complete these tasks?

Let’s see how to write the operations section that answers all the above questions:

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How do you write an operations plan section?

Writing an operations plan within a business plan involves summarizing the day-to-day tasks necessary to run the business efficiently and meet its goals in both the development and manufacturing phases of the business.

Here’s a step-by-step guide:

1. Development phase

In this stage, you mention what you’ve done to get your business operations up and running. Explain what you aim to change and improvise in the process. These are the elements your development section will contain:

Production workflow

Explain all the steps involved in creating your product. Provide a detailed description of each step, including any inefficiencies and the actions needed to address them. Here, you also mention any inefficiencies that exist and talk about the actions that need to be taken to tackle them.

Write down the risks involved in the production and potential problems you may face later down the line. State the safety measures employees take to avoid any misfortune while working. Explain how you store hazardous material and discard waste.

Mention any industry organizations and associations you’re a part of or plan to join. It’s essential to include this information to convey to the reader that you’re aware of the organizations and associations in your industry.

Supply chains

Here, you mention the vendors you work with to sell your products. Give a quick rundown of the agreements you signed with them. Mention the terms and conditions, prices, and timeframe of the contract. You can also mention if you have any backup suppliers if the existing ones fail to fulfill the requirements.

Quality control

Describe the measures you’re taking to assure and verify the quality of the end product. If you’re working towards getting a product certification, explain the steps you take to meet the set standards.

2. Manufacturing phase

The development stage acquaints the reader with the functioning of your business, while the manufacturing stage describes the day-to-day operation. This includes the following elements:

Outline of daily activities

Create an outline of the day-to-day activities of the production process. This includes the hours of operation, days the business will be open, and whether the business is seasonal or not.

Mention the location of your business , other branches you have, and their locations. If available, include images or drawings of the buildings, lease documents, real estate agreements, and other relevant documents. If you include these in your plan, mention why they’re crucial.

Tools and equipment

Describe the tools and machinery you use. You should also include the cost of the equipment; these will be important to predict financial requirements.

List down all your assets. These include land, buildings, tools, machinery, vehicles, and furniture. Include a legal description and the value of these assets.

Special requirements

If you require any additional facilities like water supply or power requirements, you mention them here. Specify what you need to do or have already done to acquire permissions for these requirements.

Raw materials

Mention your raw material suppliers. If you need any extra materials, you can also include them in your operations plan. Here, you also mention the contracts and agreements with your suppliers.

Productions

Explain the production process and the time required to produce one unit. Include the factors that may disrupt the production flow. Further, mention your strategies to tackle these inefficiencies to avoid delays in manufacturing.

Here, you state the process of storing manufactured products, managing the stock, and the costs of the storage spaces. Stringent management of inventory is essential to maintain product quality and assure customer satisfaction.

Feasibility

To ensure the viability and effectiveness of your product, detail any tests it has undergone. This includes prototype testing to evaluate the design and functionality.

Additionally, highlight product or service testing, such as performance, safety, and user experience assessments. These tests validate your product’s readiness for the market, ensuring it meets customers’ needs and regulatory standards.

Include the pricing strategy for your products or services. You can also include the final prices of your products.

Outline your pricing strategy including which approach you used, for example—cost-plus, value-based, or competitive pricing. Include the final prices of your products or services, providing a breakdown if there are different tiers or packages.

Why do you need an operations plan?

An operations plan is like an instruction manual for your business. It helps investors assess your credibility and understand the structure of your operations.

Internally, an operations plan works as a guide, which helps your employees and managers to know their responsibilities. It also helps them understand how to execute their tasks in the desired manner—all while keeping account of deadlines.

The operations plan helps identify and cut the variances between planned & actual performance and makes necessary changes.

It helps you visualize how your operations affect revenue and gives you an idea of when you need to implement new strategies to maximize profits. Some of the advantages of preparing an operations plan include:

Offers clarity

Operational planning makes sure that everyone in the audience and team is aware of the daily, weekly, and monthly work. It improves concentration and productivity.

Contains a roadmap

Operational planning makes it much easier to reach long-term objectives. When members have a clear business strategy to follow—productivity rises, and accountability is maintained.

Set a benchmark

It sets a clear goal for everyone about what is the destination of the company and how to reach it.

Manages resources

It supports you in allocating resources, such as human resources, equipment, and materials, ensuring that nothing is wasted and everything is used optimally.

Helps in decision making

An operations plan helps make smart decisions by showing how the business runs day-to-day. It provides details on resources, wise investments, and effective risk management, ensuring that decisions improve overall business operations.

Operations plan essentials

Now that you have understood the importance of the operations plan, let’s go through the essentials of an operations plan:

Strategic plan

Your operations plan is fundamentally a medium for implementing your strategic plan . Hence, it’s crucial to have a solid plan to write an effective operations plan.

Having clear goals is one of the most important things for an operations plan. For clear goals, you need to think SMART:

• Specific: Clearly define what employees should achieve
• Measurable: Quantify the goal to track progress
• Attainable: Set ambitious but achievable goals
• Timely: Provide a deadline

Different departments will have their objectives, all supporting the main goal. All these strategic objectives are flexible and should align with the company’s long-term goals.

Key performance indicators

It’s essential to choose the right Key Performance Indicators (KPIs). It’s a good practice to involve all your teams while you decide your KPIs. Some of the important KPIs can be revenue growth, customer acquisition cost (CAC), net profit margin, churn rate, etc.

Creating a timeline with milestones is necessary for any business. It keeps everyone focused and helps track efficiency. If some milestones aren’t met in a certain period, then it’s time to re-evaluate them.

Examples of some milestones are:

• Hiring key team members in six months
• Setting checkpoints for different production phases like design, prototype, development, testing, etc.
• Acquiring the first 50 clients in a year

Now you’re all set to write an operations plan section for your business plan. To give you a headstart, we have created an operations plan example.

Operations Plan Example

We know this guide has been helpful for you in drafting a comprehensive operational plan section for your business plan.

If you’re still unsure or need help getting started, consider using business plan software like Upmetrics . It offers step-by-step guidance, so you won’t have to worry about what comes next.

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Frequently Asked Questions

What is the difference between a strategic plan and an operational plan.

A strategic plan outlines the long-term vision, mission, and goals of an organization, focusing on growth and direction over several years.

In contrast, an operational plan details the short-term tasks, processes, and resource allocation needed to achieve those strategic goals, emphasizing day-to-day efficiency and productivity.

What role does the operations plan play in securing funding for a business?

The operations plan defines the clear goals of your business and what actions will be taken daily to reach them. So, investors need to know where your business stands and it will prove the viability of the goals helping you in getting funded.

What are the factors affecting the operations plan?

Some of the factors that affect the operations plan are:

• The mission of the company
• Goals to be achieved
• Finance and resources your company will need

Can an operations plan be created for both start-up and established businesses?

Yes, both a startup and a small business need an operations plan to get a better idea of the roadmap they want for their business.

About the Author

Upmetrics Team

Upmetrics is the #1 business planning software that helps entrepreneurs and business owners create investment-ready business plans using AI. We regularly share business planning insights on our blog. Check out the Upmetrics blog for such interesting reads. Read more

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How to Write a Detailed Business Plan Step-by-Step [Free Template]

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12 min. read

Updated September 23, 2024

Writing a business plan is one of the most valuable things you can do for your business. 

Study after study proves that business planning significantly improves your chances of success by up to 30 percent 1 . That’s because the planning process helps you think about all aspects of your business and how it will operate and grow.

Ready to write your own detailed business plan? Here’s everything you need (along with a free business plan template ) to create your plan.

Before you write a detailed business plan, start with a one-page business plan

Despite the benefits of business planning , it’s easy to procrastinate writing a business plan. 

Most people would prefer to work hands-on in their business rather than think about business strategy . That’s why, if you’re writing a business plan for the first time, we recommend you start with a simpler and shorter one-page business plan.

With a one-page plan, there’s no need to go into a lot of details or dive deep into financial projections—you just write down the fundamentals of your business and how it works. 

A one-page plan should cover:

• • Value proposition
• • Market need
• • Your solution
• • Competition
• • Target market
• • Sales and marketing
• • Budget and sales goals
• • Milestones
• • Team summary
• • Key partners
• • Funding needs

A one-page business plan is a great jumping-off point in the planning process. It’ll give you an overview of your business and help you quickly refine your ideas.

Check out our guide to writing a simple one-page business plan for detailed instructions, examples, and a free downloadable one-page plan template .

When do you need a more detailed business plan?

While I will always recommend starting with the one-page plan format, there are times when a more detailed plan is necessary:

• • Flesh out sections of your plan: You need to better understand how your marketing, operations, or other business functions will operate.
• • Build a more detailed financial forecast: A one-page plan only includes a summary of your financial projections. A detailed plan includes a full financial forecast, including a profit and loss statement, balance sheet, and cash flow forecast to better measure performance.
• • Prepare for lenders and investors: While they may not read the full plan, any investor will ask in-depth questions that you can only answer by spending time writing a detailed business plan.
• • Sell your business: Use your business plan as part of your sales pitch, and show potential buyers all the details of how your business works.

How to write a detailed business plan

Let’s walk through writing a detailed business plan step-by-step and explore an example of what a finished business plan (for a local swim club Pools & Laps) built with LivePlan’s business plan builder looks like.

1. Executive summary

Yes, the executive summary comes first in your plan, but you should write it last—once you know all the details of your business plan. 

It is just a summary of your full plan, so be careful not to be too repetitive—keep it between one or two pages and highlight: 

• • Your opportunity: This summarizes what your business does, what problem it solves, and who your customers are. This is where you want readers to get excited about your business
• • Your team: For investors, your business’s team is often even more important than what the business is. Briefly highlight why your team is uniquely qualified to build the business and make it successful.
• • Financials: What are the highlights of your financial forecast ? Summarize your sales goals, when you plan to be profitable, and how much money you need to get your business off the ground.

For existing businesses, write the executive summary for your audience—whether it’s investors, business partners, or employees. Think about what your audience will want to know, and just hit the highlights.

2. Opportunity

The “opportunity” section of your business plan is all about the products and services that you are creating. The goal is to explain why your business is exciting and the problems that it solves for people. You’ll want to cover:

Problem & solution

Every successful business solves a problem for its customers. Their products and services make people’s lives easier or fill an unmet need in the marketplace. 

In this section, you’ll want to explain the problem that you solve, whom you solve it for, and what your solution is. This is where you go in-depth to describe what you do and how you improve the lives of your customers.

Target market

In the previous section, you summarized your target customer. Now you’ll want to describe them in much greater detail. You’ll want to cover things like your target market’s demographics (age, gender, location, etc.) and psychographics (hobbies and other behaviors). 

Ideally, you can also estimate the size of your target market so you know how many potential customers you might have.

Competition

Every business has competition , so don’t leave this section out. You’ll need to explain what other companies are doing to serve your customers or if your customers have other options for solving the problem you are solving. 

Explain how your approach is different and better than your competitors, whether it’s better features, pricing, or location. Explain why a customer would come to you instead of going to another company. 

3. Execution

This section of your business plan dives into how you will accomplish your goals. While the Opportunity section discussed what you’re doing, you now need to explain the specifics of how you will do it.

Marketing & sales

What marketing tactics will you use to get the word out about your business? You’ll want to explain how you get customers to your door and what the sales process looks like. For businesses with a sales force, explain how the sales team gets leads and what the process is like for closing a sale.

Depending on the type of business that you are starting, the operations section needs to be customized to meet your needs. If you are building a mail-order business, you’ll want to cover how you source your products and how fulfillment will work.

If you’re building a manufacturing business, explain the manufacturing process and the necessary facilities. This is where you’ll talk about how your business “works,” meaning you should explain what day-to-day functions and processes are needed to make your business successful.

Milestones & metrics

So far, your business plan has mostly discussed what you’re doing and how you will do it. 

The milestones and metrics section is all about timing. Your plan should highlight key dates and goals that you intend to hit. You don’t need extensive project planning in this section, just key milestones that you want to hit and when you plan to hit them. 

You should also discuss key metrics : the numbers you will track to determine your success.

The Company section of your business plan should explain your business’s overall structure and the team behind it.

Organizational structure

Describe your location, facilities, and anything else about your physical location relevant to your business. You’ll also want to explain the legal structure of your business—are you an S-corp, C-corp, or an LLC? What does company ownership look like?

Arguably one of the most important parts of your plan when seeking investment is the “Team” section. This should explain who you are and who else is helping you run the business. Focus on experience and qualifications for building the type of business that you want to build. 

It’s OK if you don’t have a complete team yet. Just highlight the key roles that you need to fill and the type of person you hope to hire for each role.

5. Financial plan and forecasts

Your business plan now covers the “what,” the “how,” and the “when” for your business. Now it’s time to talk about money. 

Financial forecasts

What revenue do you plan on bringing in, and when? What kind of expenses will you have? How much cash will you need?

These are the types of questions you’ll answer by creating detailed forecasts. Don’t worry about getting it perfect, these are just educated guesses. Your goal is to get numbers down that seem reasonable so you can review and revise financial expectations as you run your business. 

You’ll want to cover sales , expenses , personnel costs , asset purchases, cash , etc, for at least the first 12 months of your business. If you can, also create educated guesses for the following two years in annual totals. 

If you intend to pursue funding, it’s worth noting that some investors and lenders might want to see a five-year forecast. For most other cases, three years is usually enough.

If you’re raising money for your business, the Financing section is where you describe how much you need. Whether you’re getting loans or investments, you should highlight what and when you need it. 

Ideally, you’ll also want to summarize the specific ways you’ll use the funding once you have it. 

For more specifics, check out our write-up explaining what to include in your business plan for a bank loan .

Historical Financial statements

If your business is up and running, you should also include your profit and loss statement , balance sheet , and cash flow statement . These are the historical record of your business performance and will be required by lenders, investors, and anyone considering buying your business. 

If you don’t want lengthy financial statements overwhelming this section of your business plan, you can just include the most recent statements and include the rest within your appendix.

6. Appendix 

The final section of your business plan is the appendix . Include detailed financial forecasts here and any other key documentation for your business. 

If you have product schematics, patent information, or any other details that aren’t appropriate for the main body of the plan but need to be included for reference.

Tips to write a detailed business plan

Keep it brief.

You may not be limited to one page, but that doesn’t mean you need to write a novel. Keep your business plan focused using clear, plain language and avoiding jargon. Make your plan easier to skim by using short sentences, bulleted lists, and visuals. Remember, you can always come back and add more details.

Related Reading: 7 tips to make a high-quality business plan  

Start with what you know

Don’t worry about following a strict top-to-bottom approach. Instead, build momentum by starting with sections you know well. This will help you get information down and ultimately make you more likely to complete your business plan. 

Set time limits

You don’t have to write your business plan in one sitting. It may be more valuable to set a time limit, see how much you get done, and return to it again in another session. This will keep you focused and productive and help you fit plan writing into your other responsibilities.

Reference business plan examples

Real-world business plan examples from your industry can provide valuable insights into how others have successfully presented their ideas, strategies, and financials. Exploring these examples can inspire your own approach and offer practical guidance on what to include and how to tailor it to your specific needs.

Just be sure not to copy and paste anything.

Prioritize sections that really matter

When writing a detailed business plan, focus on the parts most important to you and your business. 

If you plan on distributing your plan to outsiders, you should complete every section. But, if your plan is just for internal use, focus on the areas that will help you right now.

Download a free business plan template

Are you ready to write your detailed business plan? Get started by downloading our free business plan template . With that, you will be well on your way to a better business strategy, with all of the necessary information expected in a more detailed plan.

If you want to improve your ability to build a healthy, growing business, consider LivePlan.

It’s a product that makes planning easy and features a guided business plan creator , drag-and-drop financial forecasting tools , and an AI-powered LivePlan Assistant to help you write, generate ideas, and analyze your business performance. 

Use your detailed business plan to grow your business

Your business plan isn’t just a document to attract investors or close a bank loan. It’s a tool that helps you better manage and grow your business. And you’ll get the most value from your business plan if you use it as part of a growth planning process . 

With growth planning, you’ll easily create and execute your plan, track performance, identify opportunities and issues, and consistently revise your strategy. It’s a flexible process that encourages you to build a plan that fits your needs.  

So, whether you stick with a one-page plan or expand into a more detailed business plan—you’ll be ready to start growth planning.

Sources in this article

• 1. Parsons, Noah. “Do You Need a Business Plan? This Study Says Yes” Bplans: Free Business Planning Resources and Templates , 10 May 2024, www.bplans.com/business-planning/basics/research .

Like this post? Share with a friend!

Noah Parsons

Before joining Palo Alto Software , Noah Parsons was an early Internet marketing and product expert in the Silicon Valley. He joined Yahoo! in 1996 as one of its first 101 employees and become Producer of the Yahoo! Employment property as part of the Yahoo! Classifieds team before leaving to serve as Director of Production at Epinions.com. He is a graduate of Princeton University. Noah devotes most of his free time to his three young sons. In the winter you'll find him giving them lessons on the ski slopes, and in summer they're usually involved in a variety of outdoor pursuits. Noah is currently the COO at Palo Alto Software, makers of the online business plan app LivePlan.

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Production Planning - A Complete Guide

According to Gartner, the global manufacturing operations management (MOM) market size is expected to reach $6.8 billion by 2023. Further on, research by KPMG suggests that 73% of manufacturers are using artificial intelligence (AI) to improve production planning.

This is supported by the results of a survey conducted by McKinsey, according to which 78% of manufacturers are using advanced analytics to improve production planning. Lastly, according to a survey by PWC, 87% of manufacturers are using cloud-based solutions to improve production planning.

While these statistics have highlighted the importance of production planning, it has also highlighted its most recent trend of adopting cloud-based software to assist them in it.

Production planning is the act of developing a guide for the design and production of a given product or service, thereby making your production process as efficient as possible.

It thus makes complete sense that the adoption of software that will automate your key business processes will only help you reach your objective faster and more efficiently.

The main purpose of production planning is to optimize your manufacturing process, consequently reducing your manufacturing costs and maximizing your net revenue and return on investment .

Additionally, production planning helps in creating a process that takes care of customer-dependent processes like timely delivery, as well as customer-independent processes like production cycle time.

Thus, for the overall productivity and profitability of your business, it is important for you to have a complete understanding of production planning. This article will help you with that by covering the following topics:

What is Production Planning?

Difference between production planning vs. production scheduling, why is production planning important, 5 types of production planning, 5 steps to make a production plan, 3 common production planning mistakes, which production planning kpis must you track, what are the 3 most common production planning tools, how can deskera help you with production planning, key takeaways, related articles.

Production planning is the process of deciding how a product or service will be manufactured before the manufacturing process begins. Thus, it is about how you plan to manage your supply chain , raw materials and components, employees, and the physical space where your manufacturing processes take place.

It is thus an important process for manufacturers like you as it affects other important aspects of your business like:

• Supply chain management
• Production scheduling
• Material requirements planning
• Production lead time
• Resource capacity planning

Considering that production planning will also spell out everything surrounding your production targets, it will also map out all the operational steps involved and their dependencies in reaching them.

The primary goal of production planning is to design the most efficient way to make and deliver your company’s products at the desired level of quality. In fact, a well-designed production plan will help your company in increasing its output and save money by developing a smoother workflow and reducing waste.

As is evident, production planning is a broad discipline that involves much more than a focus on manufacturing process efficiency.

In fact, production planning activities include demand forecasting as well so that you will be able to determine the right mix of products to meet customer needs. Additionally, it will also help you in choosing the optimal approach to building those products.

Also, production planning will assess the resources needed to meet production goals and lay out in detail all the operations in the production process.

Lastly, production plans must include the flexibility to make operational adjustments when problems occur- such as staffing shortages, supply chain problems, and machine breakdowns.

Production Planning: Production planning is the process of determining the number of goods and services that an organization will produce in a given period of time.

It involves making decisions on the number of resources, such as raw materials, labor, and capital, that will be required to meet the desired production output.

It also involves the selection of production processes, the determination of production schedules, and the coordination of activities within the production process.

Production Scheduling: Production scheduling is the process of organizing and planning the sequence of production operations and activities in order to ensure that the desired output is achieved within the specified time frame.

It involves the allocation of resources, the determination of task sequences, and the creation of production schedules.

It also involves the coordination of activities within the production process in order to ensure that the desired output is achieved in the most efficient manner possible.

Therefore, while production planning provides an overview of what your company plans to do, production scheduling creates a more detailed view of exactly how your company will do it.

This means that the production schedule will describe when each step of your production plan will occur and consequently by using which resources and how.

Considering that a well-constructed production plan will help you boost your revenue, net profits , financial KPIs , operational metrics , and even customer satisfaction, production planning is vital for your business and its success.

In fact, a poorly designed production plan can cause production problems and even carries with it the risk of sinking your company.

Some of the specific benefits of production planning are:

Your production plan will provide you with a framework that will help you understand your resources and the production steps that you will need to undertake to meet your customers’ needs.

Additionally, it will also help you understand the potential problems that may occur during production and how you can mitigate them. This will help you improve your cash flow and the health of your financial statements . It will also help you improve customer retention .

One of the other benefits of production planning is that it will help you reduce bottlenecks and help minimize costs. This will thus keep your net working capital stronger and prepared for other uses that will lead to the growth and development of your business.

Additionally, production planning will also help you ensure that your products are of high quality and that your expenses do not exceed the budget.

Lastly, it will also help ensure that your resources are used efficiently and that wastage is avoided. In fact, production planning will also help in reducing manufacturing lead times through efficient planning and processes.

Customer Satisfaction

With production planning, you will be able to ensure that your company is able to make and deliver products to customers on time. This will lead to strong customer loyalty , as well as a positive brand image that will encourage returning customers as well as increased sales referrals .

Depending on the production method that your company uses, as well as on other factors like product type, order size, and equipment capabilities, the design of your product plan will be decided. The five types of production planning that are used most frequently are:

Batch Production Planning

This type of production planning refers to when you need to manufacture identical items in groups or in a continuous process rather than one at a time.

Batch production often leads to increased efficiency for several businesses. This leads to increased gross profits , reduction in the cost of goods manufactured , and better customer satisfaction.

For example, a clothing manufacturer making goods for the summer might first set up its cutting and sewing machines to make 500 red t-shirts, then switch to navy fabric and thread to make 400 tank tops.

A good production plan for batch processing is one that looks out for potential bottlenecks or delays when switching between batches. This will help you avoid additional expenses and maximize your profitability as well as productivity.

Job - or Project-Based Planning

Used most often by small and medium-sized businesses, here, the focus is on the creation of a single item by one person or team. Typically, job or project-based planning is used when there is a specificity of each client’s requirements, thereby making it difficult to make the products in bulk.

Several construction businesses and makers of custom jewelry and dresses adopt this production planning method to get the job done.

Flow Production Planning

Flow production is also known as continuous production, and here, the standardized items are mass-produced continuously on an assembly line. This method is most often used by large manufacturers who want to create a constant stream of finished goods.

In flow production planning, it is important that each item moves seamlessly from one step along the assembly line to the next. This will help avail the benefits of adopting flow production, which reduces costs and delays, especially when there is a steady demand for your products.

Based on the steady demand for your products and adoption of flow production, it will become easy for you to determine your needs for materials, equipment, and labor at each stage along the assembly line. This will help you streamline your production and avoid delays.

For example, companies in the automotive industry and makers of canned food and drinks use this method.

Process Production Planning

This is a method wherein there will generally be different types of machinery that are completing separate tasks to put together the finished goods.

Mass Production Planning

While this method is similar to flow production planning because it is primarily focused on creating a continuous flow of identical products, this happens at a much bigger scale. This means that by implementing this method, you would be able to cut your production costs through economies of scale.

This method will be the aptest for you when the uniformity of your products is as important as the efficiency of your production process.

Production planning is a complex and dynamic process that starts with forecasting and includes process design and monitoring. The five typical production planning steps are:

Forecast Product Demand

The first step to production planning is to estimate how much of each product you will need to produce over a given period of time.

Your historical data will be able to help you with forecasting, however, during demand planning , and consequently production planning, you will also need to take other demand-affecting factors like market trends and the economic situation of your buyer personas into consideration.

Implementing a demand planning software like Deskera MRP, which will also be able to help you with production planning, will help you make more informed decisions. This, in turn, will lead to increased profits, productivity, and more satisfied customers.

Map Out Production Steps and Options

In this step of production planning, you will be determining the resources, steps, and processes that you will need to produce the required output in a given time period. Here, you can also examine different options available for achieving your production goals, like considering outsource manufacturing .

One of the added benefits of production mapping is that it will help you identify which steps are interdependent and which can be performed simultaneously.

For example, you want to produce 1,000 children’s bicycles. Manufacturing the bicycle frames consists of a series of steps that must happen in sequence - like cutting metal tubes, welding, and painting, etc. However, there are other activities that can happen simultaneously, like assembling the wheels.

Lastly, this step will also help you determine if you have all the necessary resources and the right equipment. It will also help you identify what you will need to do if your machine breaks down. In fact, production mapping will also help you determine whether your suppliers are meeting your demand on time or not.

Thus, production mapping will assist you in inventory management , keeping a check on your inventory costs , and shop floor scheduling . It will also help you improve the ratio of your operating income to operating expenses .

Choose a Plan and Schedule Production

After comparing the cost, the time required, and the risks for each option, in this step, you would select a production plan to implement. Sharing the selected plan as an executive summary with all the necessary stakeholders will help you ensure a smoother production process, as they will all be aware of what is going to be needed and when.

Then, you will create a detailed production schedule that will lay out in detail how your company will execute the plan, including the resources and timing for each step. In fact, this will set the basis for the master production schedule while shortening your order fulfillment cycle time.

Monitor and Control

Once you have completed the above steps, your production will start. This means that you will now need to track performance and continuously compare it against the target described in the production plan.

The benefit of doing this is that it will help you ensure that you are adhering to the plan as well as the schedule. Additionally, it will also help you detect any issues as soon as they pop up, letting you address them quickly, thereby mitigating the losses they might have caused.

Adjust Accordingly

It is going to be inevitable for your production to be affected by events that you cannot plan for or predict. Some of those events include supply chain lags, client specifications, equipment failures, and worker illness.

Additionally, after seeing your production plan in action, you might have even identified ways to improve it and make it more profitable.

Thus, it is crucial that you keep your production plans flexible enough to allow for adjustments when needed. This will help you improve their efficiency and profitability by huge measures.

One of the best ways to avoid or mitigate problems once production has started is by being aware of the potential pitfalls ahead of time. The three most common production planning mistakes are:

Not Anticipating Hiccups Along the Way

It is very likely that the plans will go awry in any complex production process. It is thus important that your production planning includes risk management strategies. This should also include backup plans that your company can rely on in case any problem arises. If you fail to do so, you might face serious problems.

For example, if a machine breaks on the line and you have not kept aside a budget for repairs and overtime of the workforce, then this issue will lead to financial strain on your company’s resources.

Keeping Your Distance

While implementing production management software will lead to you getting real-time visibility into your company’s production status, you should make sure that this information is supported by in-person visits to the production line.

These visits will give you valuable insights into how production is working in practice. These insights might prove useful in changing your production planning to make it more profitable and productive.

If you or your employees continue to only sit behind the desk, then you will be missing out on these valuable insights, which will even improve your several relevant key performance indicators .

Failing to Maintain Equipment

It is crucial that you regularly maintain your company’s equipment because this is what is making your production happen. Thus, you must have a strategy in place to track the usage, as well as a budget to pay for the regular preventive maintenance that will ensure that they keep running smoothly.

KPIs or key performance indicators are those important metrics that will help your company track the health of its production processes.

By monitoring KPIs and comparing them to target values defined in your production plans, you would be able to assess whether your production is on track or not.

Additionally, you would also be able to identify problems that might need addressing.

Some of the typical production planning KPIs that you must track are:

This is one of the key efficiency metrics that will track the percentage of time that production is not occurring during the scheduled operating hours. Some of the reasons why this is happening are:

• Machine breakdowns
• Tool adjustments

While some of the downtimes might be essential, like, for example, downtime for machine maintenance, generally, the lesser the downtime, the better it is.

This is also known as the changeover time and is the amount of time it takes to switch between jobs. Setup time affects overall productivity because, during these periods, production is halted.

Thus, it is important that production schedules take into consideration how much time and effort it takes to reconfigure production for each job. This includes but is not limited to the following:

• Changes to the equipment
• Changes to the raw materials
• Changes to the workforce

In order to increase your efficiency, it is important that you design your production schedules such that they minimize changeover time.

Production Rate

In a manufacturing environment, this is typically measured as the number of units produced during a specific period. The advantage of comparing the actual production rate for each process with its planned rate will help you identify your strengths as well as weaknesses. It will also help you to address your problems.

Overall Equipment Effectiveness (OEE)

This is the measure of the overall manufacturing productivity that accounts for quality, performance, and availability. The formula for OEE is:

OEE = Quality x Performance x Availability

Typically, quality is measured as the percentage of parts that meet the quality standards. Performance is how fast a process is running compared to its maximum speed, which is expressed as a percentage. Availability is the percentage of uptime during a company’s scheduled operating hours.

Thus, you can increase your OEE by lowering downtime, reducing waste, and maintaining a high production rate.

Rejection Rate

This is the percentage or number of products that have failed to pass quality checks. Depending on the nature of the product and the problem, it may be possible to salvage some of the rejected items by reworking them. However, there may be others that need to be scrapped.

On-Time Orders

Production delays can be costly in terms of reputation as well as money. This is because if you are able to generate products on schedule, then there would be fewer chances of you needing to use costly expedited shipping or other emergency measures to meet deadlines.

Additionally, delivering orders on time will keep your customers happy, which means that they are more likely to continue doing business with your company while also helping in your company’s positive brand awareness .

To build their production plans and track their progress, businesses tend to rely on a variety of tools. These tools range from visualization tools to sophisticated software that automates several of the involved steps. The three most common production planning tools are:

Gantt Charts

A Gantt chart is a detailed visual timeline of all the tasks scheduled for a particular job. This chart is an integral part of manufacturing and several other industries.

Considering that production planning involves coordinating and scheduling several tasks of your business, Gantt charts will visually represent when each task will take place and how long it will last.

However, manually creating and updating Gantt charts to reflect your complex, ever-changing production schedules is not only time-consuming but also an error-prone job.

Spreadsheets

While small companies start tracking their simple production plans using spreadsheets, for most companies, the inherent complexity of production planning quickly outstrips the capabilities of spreadsheets.

Production Planning Software

Production planning involves a wide range of activities, including but not limited to forecasting, tracking inventory, supply chain management, and scheduling jobs. This requires information from across your company and beyond.

Additionally, production planning information is integral to business operations and is used by other groups within the company, including finance.

Taking all of this into account, using MRP software like Deskera, which includes production planning software, and also provides a single solution for managing the entire business, is the best choice you can make for your company.

As a manufacturer or retailer, it is crucial that you stay on top of your manufacturing processes and resource management.

You must manage production cycles, resource allocations, safety stock, reorder points, and much more to achieve this.

Deskera MRP is the one tool that lets you do all of the above. With Deskera, you can:

• Track raw materials and finished goods inventory
• Manage production plans and routings
• Maintain bill of materials
• Optimize resource allocations
• Generate detailed reports
• Create custom dashboards

And a lot more.

It is also possible to export information and data on Deskera MRP from other systems. Additionally, Deskera MRP will give you analytics and insights to help you make better decisions.

So go ahead and book a demo for Deskera MRP today!

Production planning is the process of deciding how a product or service will be manufactured before the manufacturing process begins. Thus, it is about how you plan to manage your raw materials and components, supply chain, employees, and the physical space where your manufacturing processes take place.

The key benefits of production planning are:

• Customer satisfaction

The five main types of production plans are:

• Batch production planning
• Job or project-based planning
• Flow production planning
• Process production planning
• Mass production planning

The five steps of making your production plan are:

• Forecast product demand
• Map out production steps and options
• Choose a plan and schedule production
• Monitor and control
• Adjust accordingly

The three most common production planning mistakes are:

• Not anticipating hiccups along the way
• Keeping your distance
• Failing to maintain equipment

The key production planning KPIs that you must track are:

• Production rate
• Overall equipment effectiveness (OEE)
• Rejection rate
• On-time orders

Implementing software like Deskera MRP will ease production planning for you while also ensuring its efficiency and, therefore, productivity and profitability.

A Complete Guide on Work Order Automation

Getting Ahead of the Game: How to Anticipate Customer Demand in Manufacturing

The Executive's Guide to Streamlining Work Orders

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10.2 The Production Process: How Do We Make It?

• What types of production processes do manufacturers and service firms use?

In production planning, the first decision involves which type of production process —the way a good or service is created—best fits with company goals and customer demand. An important consideration is the type of good or service being produced, because different goods may require different production processes. In general, there are three types of production: mass production, mass customization, and customization. In addition to production type, operations managers also classify production processes in two ways: (1) how inputs are converted into outputs and (2) the timing of the process.

One for All: Mass Production

Mass production , manufacturing many identical goods at once, was a product of the Industrial Revolution. Henry Ford ’s Model-T automobile is a good example of early mass production. Each car turned out by Ford ’s factory was identical, right down to its color. If you wanted a car in any color except black, you were out of luck. Canned goods, over-the-counter drugs, and household appliances are other examples of goods that are mass-produced. The emphasis in mass production is on keeping manufacturing costs low by producing uniform products using repetitive and standardized processes. As products became more complicated to produce, mass production also became more complex. Automobile manufacturers, for example, must now incorporate more sophisticated electronics into their car designs. As a result, the number of assembly stations in most automobile manufacturing plants has increased.

Just for You: Customizing Goods

In mass customization , goods are produced using mass-production techniques, but only up to a point. At that point, the product or service is custom-tailored to the needs or desires of individual customers. For example, American Leather , a Dallas-based furniture manufacturer, uses mass customization to produce couches and chairs to customer specifications within 30 days. The basic frames in the furniture are the same, but automated cutting machinery precuts the color and type of leather ordered by each customer. Using mass-production techniques, they are then added to each frame.

Customization is the opposite of mass production. In customization, the firm produces goods or services one at a time according to the specific needs or wants of individual customers. Unlike mass customization, each product or service produced is unique. For example, a print shop may handle a variety of projects, including newsletters, brochures, stationery, and reports. Each print job varies in quantity, type of printing process, binding, color of ink, and type of paper. A manufacturing firm that produces goods in response to customer orders is called a job shop .

Some types of service businesses also deliver customized services. Doctors, for instance, must consider the illnesses and circumstances of each individual patient before developing a customized treatment plan. Real estate agents may develop a customized service plan for each customer based on the type of house the person is selling or wants to buy. The differences between mass production, mass customization, and customization are summarized in Exhibit 10.5 .

Converting Inputs to Outputs

As previously stated, production involves converting inputs (natural resources, raw materials, human resources, capital) into outputs (products or services). In a manufacturing company, the inputs, the production process, and the final outputs are usually obvious. Harley-Davidson , for instance, converts steel, rubber, paint, and other inputs into motorcycles. But the production process in a service company involves a less obvious conversion. For example, a hospital converts the knowledge and skills of its medical personnel, along with equipment and supplies from a variety of sources, into health care services for patients. Table 10.1 provides examples of the inputs and outputs used by various other businesses.

There are two basic processes for converting inputs into outputs. In process manufacturing , the basic inputs (natural resources, raw materials) are broken down into one or more outputs (products). For instance, bauxite (the input) is processed to extract aluminum (the output). The assembly process is just the opposite. The basic inputs, like natural resources, raw materials, or human resources, are either combined to create the output or transformed into the output. An airplane, for example, is created by assembling thousands of parts, which are its raw material inputs. Steel manufacturers use heat to transform iron and other materials into steel. In services, customers may play a role in the transformation process. For example, a tax preparation service combines the knowledge of the tax preparer with the client’s information about personal finances in order to complete the tax return.

Production Timing

A second consideration in choosing a production process is timing. A continuous process uses long production runs that may last days, weeks, or months without equipment shutdowns. This is best for high-volume, low-variety products with standardized parts, such as nails, glass, and paper. Some services also use a continuous process. Your local electric company is an example. Per-unit costs are low, and production is easy to schedule.

In an intermittent process , short production runs are used to make batches of different products. Machines are shut down to change them to make different products at different times. This process is best for low-volume, high-variety products such as those produced by mass customization or customization. Job shops are examples of firms using an intermittent process.

Although some service companies use continuous processes, most service firms rely on intermittent processes. For instance, a restaurant preparing gourmet meals, a physician performing surgical procedures, and an advertising agency developing ad campaigns for business clients all customize their services to suit each customer. They use the intermittent process. Note that their “production runs” may be very short—one grilled salmon or one physical exam at a time.

Concept Check

• Describe the different types of production processes.
• How are inputs transformed into outputs in a variety of industries?

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Want to cite, share, or modify this book? This book uses the Creative Commons Attribution License and you must attribute OpenStax.

Access for free at https://openstax.org/books/introduction-business/pages/1-introduction

• Authors: Lawrence J. Gitman, Carl McDaniel, Amit Shah, Monique Reece, Linda Koffel, Bethann Talsma, James C. Hyatt
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• Book title: Introduction to Business
• Publication date: Sep 19, 2018
• Location: Houston, Texas
• Book URL: https://openstax.org/books/introduction-business/pages/1-introduction
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What is Production Planning? Process & Strategies

by Oliver Munro

Posted 24/10/2023

Efficiency in manufacturing comes from having the right preparation and the most cost-effective processes in your arsenal. The first step in achieving these aims is called production planning.

Production planning is where you map out how your business will operate – the resources, strategies, equipment, and labour required to hit your production goals. Stay tuned as we explore this topic and uncover how you can get the most out of your production planning process.

What is production planning?

Production planning is the process of developing a strategy for the production of a company’s products and services. It describes how goods will be manufactured, the expected demand for those goods, and any production requirements such as materials or labour.

In most cases, the production planning process will outline the company’s production goals and how they’ll track success, as well as include a schedule for ensuring products are made in time to meet the forecasted demand.

A production plan should consider all aspects of operating a manufacturing business .

Common elements found in a production plan include:

• Production targets
• Manufacturing processes
• Workforce and equipment requirements
• Goals and KPIs
• Production schedules
• Market analysis
• Demand forecasting
• Quantities of materials required

Production planning allows manufacturers to optimise processes and reduce lead times before production begins, or before making any major investments. It also lowers the risks of overproduction and stockouts, greatly increasing the likelihood that production jobs will be finished on time and to the standard customers expect.

What is a production plan?

A production plan is the deliverable which comes out the other end of the production planning process. This document describes in detail every step of the production process investigated and outlined during the planning phase.

Think of your production plan as an instruction manual for manufacturing your products – it tells you what to do and what you’ll need to do it.

Production planning vs production scheduling

Production planning and production scheduling deal with different stages of the manufacturing process. Where production planning provides a top-level overview of how you intend to produce the goods and services customers need, production scheduling is where you get into the weeds of how a product will be made – for example, the exact production times and labour allocation required.

At the end of the production planning process, you will have a detailed plan for achieving your production goals. Production scheduling is the act of putting that plan into action.

The production scheduling process notes down specific times, dates, and deadlines, checks for conflicts and interdependencies, and sets production into motion. It can be a more complex process to manage, particularly when it involves multiple products.

Advantages of production planning

Effective production planning helps companies minimise the cost of manufacturing products while improving customer satisfaction and company profitability . When you have a tight production plan based on accurate forecasting and data analysis, your business will be in a better financial position.

The main benefits of production planning include:

• Business-wide visibility: A production plan lays out all the manufacturing processes and required materials, including what you need to procure and what’s already available. This bird’s eye view of your resources paints a complete picture of your company’s financial health and current production capacity.
• More efficient processes: Production planning highlights inefficiencies, bottlenecks, and causes for concern in your existing manufacturing systems – before production begins. This enables you to tighten up or rethink your approach in advance, so you don’t waste money or effort on slow processes.
• Lower production costs : When your production plan is based on accurate forecasting and careful assessment of your production needs, there will be many opportunities to reduce your expenditure through more efficient processes and smarter purchasing decisions.
• Reduced waste: Optimising processes and inventory means gaining a more accurate understanding of your requirements. When you can identify the wasteful activities and excessive resources slowing you down – and how to eliminate them – your business will operate more productively and be more cost-effective.
• Improved customer satisfaction: Proper production planning helps to reduce manufacturing lead times so customers can receive orders sooner. It also helps prevent missed sales caused by stockouts, as you’re more likely to have the resources and inventory available to meet demand.

In summary, production planning equals improved productivity and cost savings; productivity equals happier customers and faster production; and cost savings result in more revenue and higher margins.

While smaller firms with simple production requirements may be able to survive for a while without any formal production planning in place, it’s an essential process for any business producing a variety of products or dealing with complex manufacturing requirements.

Next, let’s look at the different types of production planning that exist.

5 types of production planning

There are five common types of production planning methods manufacturers may find useful. Here’s a quick recap of what they are and who they’re effective for.

1. Batch production planning

Batch production refers to the production of many similar items all at once – as opposed to producing items individually or one by one. Batch production planning is how you prepare for this method of manufacturing. It involves determining how to maximise resources without causing overproduction or excessive downtime.

In batch production, assembly is generally completed in steps. Items go through the first step of the production process and are then queued for the next stage of the process. This method is known as batch and queue. When performing batch production planning, it’s helpful to identify specific bottlenecks that occur between batches – or when items are in the queue stage.

2. Job production planning

Job-based production planning, also known as shop or project-based production planning, refers to the production of items one item at a time, either by a single craftsperson or a team.

Often used by smaller or medium-sized manufacturers, job shop production planning is beneficial in circumstances where it’s difficult to bulk-produce a line of products, such as custom furniture.

Job production planning should focus on ensuring there is capacity for customer-requested customisations in the production plan. This may mean purchasing or preparing extra resources, which can be dangerous for more complex jobs, so accurate forecasting is especially important.

3. Flow production planning

Flow production refers to the continuous production of similar and consistently in-demand goods. Flow production planning generally focuses on the assembly line, where the standardisation of goods and equipment can allow for a highly efficient (and constant) flow of production to take place.

The flow production method aims to minimise the amount of finished goods and work-in-process inventory . Correct planning and preparation improve efficiencies and reduce costs right along the supply chain, making it a beneficial practice for you as well as your suppliers and B2B customers.

4. Mass production planning

Mass production planning is the process of prepping to manufacture a large number of identical items in a short time. Because items subject to mass production typically follow the same production process, factory automation and assembly line optimisation are key areas to focus on.

When you’re creating a plan for mass production, it’s helpful to look for ways to reduce changeover time and increase total production output. The benefits of doing so will have a compounding effect wherein a single optimisation, applied to a large quantity of items, results in a massive time or cost saving.

5. Process manufacturing planning

Process manufacturing, or process production, refers to the manufacturing of items that require predetermined formulas or recipes to produce. Unlike discrete manufacturing, process manufacturing deals with goods that are not typically measured in discrete units such as liquids or gases.

Planning for process manufacturing is crucial because of long changeover periods and a high risk of botched production due to errors. This method can also result in a lot of waste, so it’s especially important to try to minimise the number of resources consumed in production.

• Related: The Ultimate Manufacturing Guide for Production Firms

Production planning process explained

The elements of a perfect production plan are exclusive to each business. In other words, what works for another business may not work for you.

Keeping that in mind, there are some distinct steps in the production planning process that almost every manufacturer ought to follow. Here’s a breakdown of what a typical production planning process might look like.

1. Forecast demand

The first step in the production planning process is to determine your upcoming production requirements based on predicted demand for products.

Demand forecasting involves leveraging historical sales data and analytics to estimate future sales.

This information can be used to set your production goals and can be extrapolated to break inventory and labour requirements for an entire period. Additionally, market research can help you predict whether demand is going to change based on external factors such as product popularity and seasonality.

To ensure accurate demand forecasting, many firms rely on inventory optimisation software to automate the number-crunching and data collection processes.

2. Determine inventory needs and production capacity

Once you have an idea of what products you’ll need to manufacture and their quantities, the next step is to figure out how that translates into materials, resources, and labour.

First, you’ll want to determine the quantities of raw materials and components needed to match the requirements of your forecasted demand levels for each product. It’s also important to note down the machinery and staffing needed to turn those materials into finished goods.

How you manage inventory impacts the efficiency with which you can operate on any given day. Effective inventory management results in less waste and wider profit margins. It also ensures you’re making the best use of your storage facilities.

Your organisation’s current production capacity will tell you if you’re ready to tackle the upcoming period’s schedule – or let you know whether you need to consider hiring more staff, renting or buying more equipment, or outsourcing work to third parties.

3. Map out production steps

After confirming how much resources and production time will be needed, it’s time to map out the processes and steps required to produce your goods. This includes identifying any equipment, tools, and service providers you may need.

Once you’ve mapped out your production steps, you’ll be able to work out which processes can be done simultaneously, which are dependent on each other, and which ones need to be outsourced. It’s also a chance to prepare contingencies in case of equipment failure or other issues.

All this feeds into the foundation of the next step in the process: creating your production schedule .

4. Production scheduling

The production scheduling phase is where you assign tasks to your various workstations, communicate the plan to relevant stakeholders, and plot timelines for each stage of production.

This can be a complex effort, which is why accurate data is vital for the earlier planning stages.

Your production schedule should include how, when, and where items will pass through the various stages of manufacturing – and who is responsible for ensuring they do so successfully.

• Learn more about Access' advanced production planning and scheduling software, Orchestrate

5. Production control and continuous improvement

Once production has begun, monitor your progress and look for further opportunities to improve or optimise specific processes.

Tracking your performance against your goals and deadlines offers two distinct benefits: It allows you to act quickly to resolve unforeseen challenges, and it tells you how accurate or effective your production planning method was this time around.

As you collect production data, use it to make continuous improvements to the way things are run. Rather than look at your production plan as a one-and-done project, think of it as the beginning of a cycle of constant optimisation.

How to schedule a production plan

Production scheduling is a process involving turning your production plan into an actionable timeline with all the necessary details laid out for the involved parties to access.

To schedule a production plan, you’ll need to go through these four phases:

• Routing: Figure out each step in the journey your raw materials take from the supply chain to the final product. Is it the most economical process or can it be improved?
• Scheduling & Communication: Take your plan and the steps written out in the prior phase and attach dates and timelines to them. Then communicate those expectations to key stakeholders.
• Dispatch & Execution: Dispatching is the giving of orders to personnel and assigning people to their tasks. Execution is the delivery of those actionable tasks.
• Maintenance: This refers to any on-the-fly adjustments of a production schedule necessary to eliminate bottlenecks once production has begun. It involves monitoring and optimising each aspect of your production plan.

Remember the importance of clear communication when it comes to scheduling a production plan. The more time you spend on getting everybody up to speed in the beginning, the less time you’ll have to spend repeating instructions or fixing mistakes later.

Production planning strategies

Let’s take a quick look at some of the strategies you can use to optimise your production planning process. Keep in mind your specific business needs and only use the information that’s relevant to you.

1. Make-to-stock strategy

Make-to-stock refers to producing items to stock them on your shelves until customers buy them.

It’s a particularly useful method in any industry where customers may wish to view an item before purchasing it, such as a car or a musical instrument.

This production planning strategy can increase inventory holding costs and therefore requires accurate demand forecasting. Consider using specialised software to ensure better predictions.

2. Make-to-order strategy

Make-to-order refers to the production of goods only when a customer has placed their order.

Businesses that manufacture unique items or offer a high degree of customisation can benefit from this strategy because it ensures that production always matches demand.

This method typically has slower lead times, but also lower holding costs.

3. Assemble-to-order strategy

Assemble-to-order (or make-to-assemble) is a common production planning strategy among companies which produce perishable goods, as it involves holding all the raw materials you might need but only assembling the product when a customer order comes in. Cake manufacturers, for example, would use an assemble-to-order production plan.

This method results in similar holding costs to make-to-stock strategies, but it can help reduce the chance of wastage and obsolescence; you’re not at risk of producing products customers won’t buy.

4. Chase strategy

A chase strategy refers to the idea of chasing demand with production. In this way, it is also known as a demand-driven production planning strategy.

Following the chase strategy, goods are only made when there is demand for them and production increases or diminishes as demand changes. Companies producing seasonal goods can benefit from applying a chase strategy.

Generally, production planning with this method assumes there will be no leftover stock after the demand wave has died down.

5. Level production

The opposite of a chase strategy is level production, whereby production is constant throughout the year and units are produced equally regardless of the time of year or customer demand.

This production planning strategy is common among manufacturers with cyclical product demand. Snowboard manufacturers, for example, know that demand falls in summer and picks up again before winter.

Inventory holding costs can be quite high in level production. Materials are still stocked to full capacity even when demand is low, but it levels out again during the busy season.

Production factory layout plan: Tips for optimising

Good factory layout planning is key to optimal production and is something you should be considering during the production planning process as it’s your best opportunity to make changes before production begins.

Here are some quick tips for optimising your production factory layout plan:

• Leave room for growth: It’s expensive and disruptive to redesign your factory layout while production is underway. If possible, leave room for flexibility in case of unforeseen changes in production volume or equipment.
• Keep similar manufacturing processes near each other: Keep similar or compatible workstations in close proximity to one another to allow goods to move more efficiently from one stage of production to the next. For example, if drilling follows cutting then see if your drilling machine will slot in beside your drop saw.
• Plan for waste: Where is your waste output going to go? You might require floor space for different types of waste, such as waste which must be thrown out and waste which can be recycled.
• Collaborate with staff: Factory floor planning is best achieved in collaboration with the people who walk that floor every day. Ask your staff where they think the layout could be optimised and what equipment or access might facilitate smoother production.

Finally, don’t forget to consider the cost of making changes to your factory layout.

You may need to close the entire assembly line for a day (or more) to install new equipment, install a mezzanine, or reorganise aisles. In addition to the cost of new equipment, consider how much you’ll lose if manufacturing must be paused.

Production planning KPIs and metrics

When you move from the planning phase into the execution of your manufacturing processes, you’ll need a way to objectively monitor progress.

That’s where these common production planning KPIs can help:

• Production rate: the number of units you’re producing per hour or day.
• Capacity rate: how close your equipment and workforce get to full capacity.
• Downtime: how much of your manufacturing time is unproductive.
• On-time delivery rate: the number of orders delivered on schedule, at the quality expected.
• Rejection rate: the number of products which fail quality control checks.
• Cost per unit: what it costs your business to produce one single unit.

For a longer list of production planning and management metrics, including formulas and definitions, check out our complete guide to manufacturing KPIs .

More posts like this:

• Production Management: Definition, Tools, Processes
• How to Create a Production Schedule (with Example & Tips)
• Cost of Production: Formula & 9 Types of Product Costs

By Oliver Munro

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The contract, the second that workers have voted down, was opposed by 64 percent of those voting, according to the union, the International Association of Machinists and Aerospace Workers. The union represents about 33,000 workers, but it did not disclose how many voted on Wednesday.

“There’s much more work to do. We will push to get back to the table, we will push for the members’ demands as quickly as we can,” said Jon Holden, president of District 751 of the union, which represents the vast majority of the workers and has led in the talks. He delivered that message at the union’s Seattle headquarters to a room of members chanting, “Fight, fight.”

Boeing declined to comment on the vote, which was a setback for the company’s new chief executive, Kelly Ortberg, who is trying to restore its reputation and business with a strategy he described in detail earlier on Wednesday . In remarks to workers and investors, Mr. Ortberg said Boeing needed to undergo “fundamental culture change” to stabilize the business and to improve execution.

“Our leaders, from me on down, need to be closely integrated with our business and the people who are doing the design and production of our products,” he said. “We need to be on the factory floors, in the back shops and in our engineering labs. We need to know what’s going on, not only with our products, but with our people.”

Mr. Ortberg delivered that message alongside the company’s quarterly financial results, which included the loss of more than $6.1 billion. This month, Boeing also announced plans to cut its work force by about 10 percent, which amounts to 17,000 jobs. The company also recently disclosed plans to raise as much as $25 billion by selling debt or stock over the next three years as it tries to avoid a damaging downgrade to its credit rating. The strike is costing the company tens of millions of dollars each day, according to various estimates.

The negotiations have been contentious. The strike began on Sept. 13 after 95 percent of workers voting rejected an earlier contract offer that had been backed by union leaders and Boeing. Later that month, the company made what it described as its “best and final” offer. The company gave workers just days to approve or reject it, but leaders of the union never put it to a vote. Boeing eventually rescinded the offer, with talks breaking down this month.

The two sides arrived at the now-rejected deal only after the Biden administration got involved. Senior administration officials had been working closely with Boeing and the union in recent months, at President Biden’s direction. Last week, Julie Su, the acting labor secretary, flew to Seattle to meet with company executives and union officials. On Wednesday, Mr. Holden said he planned to ask the White House to continue to try to help the parties find a resolution.

Boeing is important to the United States as an economic engine and as a symbol of manufacturing prowess. It employs almost 150,000 people across the country — nearly half in Washington State — and is one of the nation’s largest exporters. The company also makes military jets, rockets, spacecraft and Air Force One.

Under the contract, workers would have received cumulative raises of nearly 40 percent over four years, a significant increase over the rejected offer and approaching what the union initially sought. The offer included a $7,000 one-time bonus and additional contributions to retirement plans. It also would have preserved an incentive bonus program that the initial rejected offer would have replaced.

Boeing machinists make about $75,000 in average annual pay. Over the last decade, the workers have seen raises under the union contract of 8 percent and more than $4 an hour in additional cost-of-living adjustments, according to the company. Consumer prices in the Seattle area have risen more than 40 percent over the past decade, according to federal data.

But the contract did not revive a defined-benefit pension plan that was frozen a decade ago — an important priority for many union members. Many workers have been furious over that loss for years, and some have said that they felt Boeing had bullied them into agreeing to the freezing of the pension. Workers have also been angry with the leadership of the union’s parent organization, which they say scheduled the vote in a way that supported approval of the offer, prompting a rule change that limited the authority to schedule votes to local union chapters.

“There’s some deep wounds,” Mr. Holden told reporters after announcing the vote results. Mr. Holden also said that the union may explore what he called hybrid defined-benefit programs in negotiations.

On Wednesday afternoon, union members streamed in and out of the Angel of the Winds Arena in Everett, Wash., one of the voting locations and a short drive from a large Boeing factory. A handful held signs and handed out fliers urging others to reject the offer.

In interviews, several said they voted against the offer because they believed the union could hold out for better terms on wages, retirement, health coverage and other benefits. Many said they were frustrated over the lost pension, even if the odds of getting it restored remain in doubt.

“How do they expect to have anybody stay at the company if they don’t have some kind of a pension plan or better investments?” said Darryl Shore, who has worked at Boeing in different roles since 1989.

Mr. Shore said he grew up in the area and both his parents worked at Boeing, but that jobs at the company today don’t hold the same economic promise they did back then.

The rejection of the new contract comes as Boeing is trying to recover from a crisis that began when a panel fell off a 737 Max jet during an Alaska Airlines flight in January, reigniting concerns about the quality and safety of Boeing’s planes. Five years earlier, two fatal Max crashes led regulators worldwide to ground the plane for nearly two years.

After the January episode, the Federal Aviation Administration limited production of the Max, Boeing’s best-selling plane. The company has since increased inspections, added training for new hires, started to simplify procedures and limited tasks performed out of sequence.

The contract’s defeat is also bad news for the manufacturer’s many suppliers. Spirit AeroSystems, which makes the body of the 737 Max and has agreed to sell itself to Boeing, recently announced plans to furlough about 700 employees, starting next week, because of the strike.

The contract being negotiated would replace one that was agreed to in 2008 and extended multiple times. That offer came together only after a two-month strike that led to a decline of more than $6 billion in revenue and a delay in delivering more than 100 airplanes that year, Boeing said at the time.

Niraj Chokshi writes about aviation, rail and other transportation industries. More about Niraj Chokshi