Master Production Scheduling (MPS) is an essential tool in the apparel industry, acting as a crucial link between sales and manufacturing. It plays a pivotal role in production planning by determining what needs to be produced based on customer demand. MPS helps in calculating capacity requirements and drives the Material Requirement Plan (MRP).
Understanding MPS in the Apparel Industry
The apparel industry operates on varying demand patterns, necessitating a structured approach to production. MPS ensures that businesses:
- Align production with customer demand.
- Optimize resource utilization.
- Reduce lead times and inventory costs.
- Provide accurate delivery commitments.
Developing MPS – Step-by-Step
Step 1: Develop Preliminary MPS A preliminary MPS is created based on:
- Sales forecasts
- Projected orders
- Historical demand patterns
For instance, an apparel manufacturer planning winter jackets for both domestic and international markets will use market data to predict the number of units to produce.
Step 2: Rough-Cut Capacity Planning (RCCP) Once the preliminary MPS is developed, Rough-Cut Capacity Planning (RCCP) checks whether:
- Bottleneck operations (e.g., stitching, dyeing) have enough capacity.
- Labor availability is adequate to meet production demands.
- Critical materials (e.g., specialized fabrics, trims) are available.
For example, a denim manufacturer in India producing jeans for both domestic and European markets will check whether their weaving and dyeing facilities can handle the forecasted demand.
Step 3: Resolving Differences Between MPS & Capacity If there is a mismatch between MPS and available capacity, adjustments are made by:
- Shifting production schedules.
- Allocating additional resources.
- Adjusting sales commitments.
For example, if a factory producing designer handbags in Italy receives more orders than expected, it may extend production shifts or outsource part of the work.
Final Assembly Schedule (FAS) in the Apparel Industry
Final Assembly Schedule (FAS) is used where products have multiple variations or customization options. It is critical in Assemble-to-Order (ATO) and Make-to-Order (MTO) environments.
- ATO (Assemble-to-Order): Basic components (e.g., fabric, buttons, zippers) are manufactured first, and final assembly happens after receiving the customer's order.
- MTO (Make-to-Order): The entire product is produced only after an order is placed.
For example, a sportswear company selling customized jerseys manufactures the fabric and components in advance. However, the final printing of team names and logos happens only after the customer places an order.
Time Horizon in MPS
MPS must cover a period at least equal to the time required to accomplish production. The Time Horizon helps plan:
- Raw material procurement.
- Production lead times.
- Inventory management.
For example, a fashion brand launching a summer collection must finalize MPS 6 months in advance to ensure on-time delivery to retail stores.
MPS and Delivery Promises
MPS determines Available-to-Promise (ATP), which helps in managing customer expectations for order fulfillment.
ATP Calculation:
- ATP for period 1 = On-hand inventory + MPS quantity - cumulative demand before the next MPS week.
- ATP for next week = MPS quantity to be received - cumulative demand.
- If new customer orders are added, ATP is adjusted.
For example, a luxury handbag brand with limited production capacity uses ATP to ensure high-demand products are allocated fairly across global retailers.
Projected Available Balance (PAB)
Projected Available Balance (PAB) helps track future inventory levels based on:
- Current stock levels.
- Planned production.
- Incoming customer orders.
Before Time Horizon: PAB = Prior period PAB + MPS - Customer orders.
After Time Horizon: PAB = Prior period PAB + MPS - (Customer orders or forecast, whichever is higher).
For example, a high-end fashion brand producing limited-edition shoes tracks PAB to ensure they don't overcommit stock to multiple retailers.
Time Fences in MPS
Time fences act as boundaries within the planning horizon to manage schedule flexibility.
Types of Time Fences:
- Demand Time Fence (DTF):
- No schedule changes are allowed within this period.
- Prevents disruptions in production.
- Planning Time Fence (PTF):
- Some schedule changes are allowed.
- Helps adjust production based on updated forecasts.
- Release Time Fence (RTF):
- Controls when production orders are released.
MPS Time Fence Zones Explained:
For example, a T-shirt manufacturer producing customized designs will have a Frozen Zone for immediate orders, while future orders remain in the Liquid Zone for flexibility.
Real-World Applications of MPS in the Apparel Industry
Domestic Market Example: A leading Indian fashion retailer supplies apparel to domestic multi-brand outlets. MPS is used to:
- Align production with seasonal demand.
- Ensure timely raw material procurement.
- Prevent overproduction and markdown losses.
International Market Example: A Bangladesh-based garment factory supplies major European brands using MPS to:
- Maintain a balance between standard and custom orders.
- Optimize fabric inventory and reduce waste.
- Meet Just-in-Time (JIT) delivery schedules.
Conclusion
Master Production Scheduling (MPS) is an essential tool in the apparel industry, ensuring:
- Optimal resource utilization and minimal production bottlenecks.
- Efficient planning in both domestic and international markets.
- Timely fulfillment of customer orders while maintaining inventory control.
By integrating MPS with RCCP, ATP, and Time Fences, apparel manufacturers can enhance efficiency, reduce lead times, and improve profitability.
References
Books
1. Vollmann, T. E., Berry, W. L., Whybark, D. C., & Jacobs, F. R. (2005). Manufacturing Planning and Control for Supply Chain Management. McGraw-Hill Education.
2. Chopra, S., & Meindl, P. (2019). Supply Chain Management: Strategy, Planning, and Operation. Pearson.
3. Carr, L. P., & Kaynak, H. (2007). Management of Operations. McGraw-Hill Education.
4. Abernathy, F. H., Dunlop, J. T., Hammond, J. H., & Weil, D. (1999). A Stitch in Time: Lean Retailing and the Transformation of Manufacturing—Lessons from the Apparel and Textile Industries. Oxford University Press.
Industry Reports & Whitepapers:
1- McKinsey & Company (2021). The State of Fashion 2022. Discusses trends in apparel production planning and supply chain efficiency. Available at: www.mckinsey.com
2- Apparel Resources (2023). Master Production Scheduling in Apparel Manufacturing: A Key to Demand-Driven Planning. Covers case studies on MPS implementation. Available at: www.apparelresources.com
Online Articles & Case Studies:
1- APICS (2022). Master Scheduling and its Importance in Apparel Manufacturing.
2- Textile Today (2023). How Apparel Manufacturers Use Master Scheduling for Efficient Production.
3- Infor (2023). M3 ERP for Fashion: How MPS Improves Apparel Manufacturing. Discusses how ERP systems support MPS. Available at: www.infor.com
Note- All the images are generated by Google Gemini and Microsoft Copilot
About the Author:
Prafull Sundriyal is a seasoned professional in Supply chain management with a solid academic background, holding an MFTech degree from NIFT Bengaluru and a BTech in Mechanical Engineering. With over five years of extensive experience in the Apparel and Fashion Industry, he has effectively collaborated with both domestic and international clients to deliver optimized solutions and enhance operational efficiency. Currently serving as an M3 Consultant at Infor, Prafull specializes in streamlining workflows, executing timely project implementations, and reducing operational costs. His expertise encompasses Project management, Product development, Operations, Strategy, and Customer success, making him a trusted advisor for seamless system transitions and impactful business outcomes.