Rebuild next week's production schedule after the mill outage

What is going on

The hammer mill will be down on Monday and Tuesday for the hammer and screen change and blender 2 is out of service until the interlock is replaced and tested. Together these take about 6,000 bags out of next week's plan. Two orders cannot move: the Brightline Hardware Group private label adhesive, 4,200 bags due Thursday, and the Northern Rivers Tiling Cooperative order of grout and adhesive, 2,600 bags due Friday. The stock records shows some cover on standard adhesive but almost none on the private label product. Townsville has spare capacity on the render range. Lucy Anand wants a rebuilt schedule with the impact on other orders, stock cover and the overtime or Saturday shift required, ready for Monday's planning meeting.

Your brief

Rebuild the weekly production schedule around the reduced capacity so that the two fixed orders ship on time, using stock cover, resequencing, Townsville capacity and additional shifts where justified, and present the schedule with the impact on other orders and the resources needed.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the batch preparation, blending and packing procedure for changeover and blend time constraints, and review the maintenance work orders for the mill and blender 2 dates.
• Extract current stock cover for each product from the finished goods stock sheet Lucy Anand has provided and identify which orders can be met from stock and which need production.
• List all orders due next week from the batch and production log and the dispatch plan, and classify them as fixed, movable or partially movable.
• Build a day by day schedule for blender 1 and the packer that sequences products to minimise changeovers and meets the two fixed orders first.
• Assess whether Townsville can take the render volume and what freight and lead time that adds, and whether a Saturday shift on blender 1 is justified.
• Check the schedule against the fatigue limits in the fitness for work policy before proposing overtime, and record the crew required.
• Prepare a one page schedule summary showing what moves, by how much, the stock position at the end of the week and the resources requested, for Lucy Anand.

What someone in this role would produce

• Rebuilt weekly production schedule
• Stock cover analysis
• Impact list of moved orders with new dates
• Resource request for overtime or Saturday shift