What is Advanced Planning and Scheduling (APS)?

What is Advanced Planning and Scheduling?

Advanced Planning and Scheduling (APS) refers to a set of software tools and methodologies used in manufacturing, production, and supply chain management to enhance the efficiency and effectiveness of planning and scheduling processes. Its main purpose is to inform production decisions around capacity and resource utilisation.

APS is a powerful alternative to T-cards, whiteboards, project management software and the ‘gut feel’ / experience of planners. Multiple tasks, constraints, dependencies and activities such as preventative maintenance, quality control and buffers and media planning are brought together in a way which traditional methods can’t match. 

APS tools balance demand and resource availability, making it easier to determine the most efficient and cost-effective way to make a product - when, how and the resources required. Managers can anticipate material and labour needs ahead of time and make decisions based on data rather than guesswork.  

APS can be used as a standalone system, though it’s often deployed in conjunction with enterprise resource planning (ERP) or (MRP) software to form a comprehensive, integrated production system. 

This guide explores the key components and benefits of Advanced Planning and Scheduling, as well as the key considerations for those considering an investment in a production planning and scheduling software or APS system.

What are the key components of APS?

Here are the main components of an Advanced Planning and Scheduling (APS) system:  

• Demand forecasting

Demand forecasting is used to predict future demand based on historical data, order pipeline and market trends. It gives manufacturers a clearer idea of the stocking requirements and resource allocation they need to plan for at various times of the year. This may also include statistical methods such as time series analysis, regression analysis or machine learning to generate more detailed forecasts.

• Production planning and scheduling

Production planning and scheduling involves the detailed planning and sequencing of production tasks to meet clearly defined goals, which is often easier said than done when dealing with competing priorities and multiple orders requirements. A robust APS system takes key factors such as material requirements, setup times, production lead times and dependencies between tasks into account before suggesting a schedule based on efficient resource allocation.

• Capacity planning

Capacity planning can be used to assess and manage the production capabilities of equipment, machinery, staff and materials to ensure that production schedules are feasible. Real-time visibility is a key as it enables manufacturers to continuously monitor resource status, inventory levels and other production assets, and make proactive changes as opportunities and challenges arise.

• ‘What if’ analysis or production modelling

The ‘What if’ analysis (or production modelling) refers to the use of data within APS systems to simulate various scenarios to help managers assess and prepare for the potential impact of changes in demand or supply chain issues. 

• Multi-user functionality

Multi-user functionality enables different departments and teams to view and interact with live plans at the same time, always from a single source of truth. The interface should be simple and easy to update when needed, whether that’s on the shopfloor or from head office.

APS should also give you the ability to schedule operations in and around multiple constraints, for example equipment, labour and materials. 

What are the benefits of Advanced Planning and Scheduling?

While there are many advantages of successfully implementing an APS system, below we explore the main advanced planning and scheduling benefits:

Enhanced efficiency

APS allows you to schedule your resources in the most efficient way to fit in more batches. APS enables manufacturers to optimise production processes, minimising downtime and bottlenecks. This results in shorter lead times and reduces operational costs, both of which have a positive impact on profitability.  

Resource utilisation 

Optimising resource management not only maximises output but also contributes to cost savings by minimising waste, fostering a more competitive and sustainable manufacturing operation.  

Reduced lead times 

APS shortens production timelines and improves responsiveness by enhancing coordination across various stages of the production process. More agile order fulfilment also enhances a company's responsiveness to market demands.  

Cost savings 

Companies can achieve substantial cost savings by optimising resource allocation and streamlining production processes. Operational costs such as overtime labour and materials wastage are reduced, enhancing overall financial performance.  

Accurate forecasting 

APS gives manufacturers the foresight to anticipate demand, optimise inventory levels and reduce the chance of under/over stocking.  

Real-time visibility

Real-time, accurate visibility of what’s happening on your shopfloor allows for continuous monitoring and adjustment of production processes; it makes it easier for managers and senior leaders to make informed, proactive decisions. 

Customer satisfaction 

Shorter lead times and on-time deliveries feed directly into client satisfaction, helping to foster trusting relationships and a loyal customer base.  

Scenario analysis 

Scenario analysis enables companies to assess and strategise various production scenarios, taking into account potential risks and disruptions along the way. This proactive approach improves the overall resilience of manufacturing operations in the face of opportunities and uncertainties.  

Compliance 

Some manufacturing industries are heavily regulated, which is why it pays to have a structured framework for adhering to Good Manufacturing Practice (GMP), safety protocols and environmental regulations.   

Collaboration 

Cloud-based APS software improves communication and cross-functional coordination by giving teams access to a centralised system and a single source of data. This avoids the need to constantly share and update files and cuts the risk of data inaccuracies.  

Adaptability 

APS delivers greater adaptability from real-time insights into production processes. It allows manufacturers to respond to changing market conditions and unforeseen disruptions before they have a chance to dent their bottom line.  

Competitive edge

The cumulative impact of optimising production, reducing costs and making better-informed decisions means that businesses with effective APS systems are usually in a stronger position to outpace competitors in their industry. 

Environmental responsibility

Sustainability is becoming more and more important for businesses, and APS can help deliver key environmental goals by minimising waste and promoting eco-friendly practices. 

What are the 4 main challenges in implementing Advanced Planning and Scheduling (APS)?

While advanced planning and scheduling tools help improve manufacturing production and management processes,  Let’s explore key challenges that manufacturers often face when looking to implement an effective APS system: 

1. System configuration - Setting the system up at the right level of complexity is crucial. Too granular and it becomes hard to maintain and update; too high level and it lacks accuracy.
2. Resistance to change – Employees and internal stakeholders are often so used to existing processes that they fear a new system may cause disruptions to their roles or routines. Overcoming this resistance requires clear communication around the benefits and ROI of the APS system and a realistic timeline for implementation.
3. Regulatory compliance – Manufacturers need to invest time and resources in customising the APS system to meet specific compliance requirements, which may involve adapting existing processes, documenting procedures and ensuring traceability across the production cycle.
4. Training and skill development – Training is crucial to equip staff with the necessary skills to operate and make the most of the investment in an APS system. Ongoing support is essential to ensure a smooth and effective adaptation to the new technology.

What are the best APS Advanced Planning and Scheduling software solutions?

There are various APS systems available on the market and doing your research is essential to find the right fit for your business needs. Here are a few popular choices to consider: 

Access Orchestrate 

Access Orchestrate is an intuitive production planning and scheduling software designed specifically with the demands of manufacturing companies in mind. The platform offers end-to-end visibility of capacity and resources, real-time dashboards and ‘what-if’ scenario planning. It can also be easily integrated with ERP and MES platforms for complete operational coverage. 

Asprova 

Asprova APS system is designed with ‘just-in-time’ manufacturers in mind, though it can be adapted for use in other types of businesses. The advanced scheduling software optimises production planning and contributes to cost reduction by enabling organisations to use their resources in a more efficient manner.  

Simio  

Simio is a manufacturing production planning software that specialises in simulation models and risk analysis. This is a good option for companies that want to build detailed schedules that predict and plan for all eventualities, while conducting risk analysis in real time.   

Monday.com  

Monday is a flexible, all-purpose platform that is used by thousands of businesses worldwide. Although it is not specifically designed for manufacturing purposes, the user experience and ability to integrate with other systems still make it a popular choice. 

How to select the right Advanced Planning and Scheduling (APS) software for your manufacturing business

There is no one-size-fits-all solution when it comes to APS systems. The best system will depend on the specific needs and size of your business, or whether you require niche capabilities to suit a particular sector. 

1. Audit your current tools and processes

Audit your current approach to planning and scheduling in order to identify weaknesses and barriers to efficiency. This will make it easier to prioritise features and get a clearer picture of the type of APS platform that will have the most immediate impact. For instance, some businesses may value scalability more than simple UX or dynamic integrations; whereas others might need a system that does it all. 

2. Identify gaps and opportunities to build your case

Buy-in and input from internal sponsors and stakeholders will also be key to the success of any software implementation project – make sure all relevant teams are involved from the start.

3. Research different APS systems and software

Product recommendations and feedback from other manufacturing businesses are useful to help you understand the benefits and pitfalls of new software, giving you a different perspective on what’s the best fit for your business. 

4. Define your expectations in terms of ROI

Understanding return on investment is crucial to making the business case for investment in an APS system that can deliver stronger growth across clearly defined KPIs. Make sure to do your research and match requirements to the capabilities offered by different systems. 

The future of Advanced Planning and Scheduling

APS systems do not replace the job of the planner – their expertise is still needed to create and verify production plans.  

APS systems are constantly evolving to meet changing industry requirements and are already a key component of smart industry best practice. Many early adopters have already begun to benefit from AI tools, IoT devices and predictive analytics, which provide continuous streams of data to improve accuracy and insight into operations. 

Machine learning algorithms can support the planning process by analysing historical data and real-time information to predict potential issues and trends, minimising the assumptions built into plans; this helps to optimise production schedules further, which feeds into operational efficiency.