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GullySystem
Manufacturing · Solutions

Plan what to make, how much and in what order, from orders you have confirmed.

Production planning turns confirmed orders and your regular daily quantities into a plan: what to make, how much, on which machine or in which oven, and in what order. Material short for Thursday shows up on Monday, early enough to buy it. The floor works from a screen and not from a guess.

What it is

A bakery decides at five in the morning how many trays go in. A garment unit decides on Monday which line runs which style. Both decide from memory, and both are caught by the one order that was promised on a phone call and never written down.

The plan is built from what is actually committed: orders on hand, the quantities that go out every day anyway, and what the store already holds. Move a job because a machine is down, and the screen shows what it pushes into Friday.

What it replaces

What your team uses today.

The module takes over these, one at a time, so nothing has to stop while it is set up.

  • A whiteboard on the shop floor
  • A diary kept by the supervisor
  • A morning huddle to decide what to make
Where it goes wrong today

The problems this is meant to ease.

Plans made on a whiteboard

The plan lives on a board and in a supervisor’s head. It changes silently.

Shortages found late

Material runs out at the machine. Purchase had no warning.

Repeat quantities re-planned

Daily items are planned from scratch each morning. Time goes to rework.

Capacity guessed

Nobody knows how much a machine or oven can take. Orders are promised on hope.

Planned and made not compared

Output is not set against the plan. Reasons for missed jobs go unrecorded.

Inside the module

What production planning does.

Plan from confirmed orders

Orders accepted for the week come in with their promised dates. Nothing is planned against an enquiry that has not been agreed.

The quantities that repeat

Counter stock, standing orders and regular route quantities are added to the plan without anybody typing them again each morning.

Capacity in your own units

Trays, machine hours, line shifts or kilos. The oven fills on the screen before it fills in the kitchen.

Shortages before the run

Material needed against material on the rack, listed a few days out, so the purchase call goes out in time. Early is cheaper.

Reschedule and see what moves

Shift one job and the ones behind it move with it. You see which customer needs the telephone call.

Planned against actually made

Yesterday’s plan beside yesterday’s output, with the reason for the gap written by the person who knows it.

Where it gets used

What this looks like in a working week.

Illustrative scenarios, written to show the shape of the work. They are not accounts of client systems.

Orders confirmed for Thursday

The production in-charge sees confirmed orders and standing quantities together. A draft plan arrives by machine and shift.

A shortage shows up early

Material needed for Thursday exceeds stock on Monday. The storekeeper raises a purchase request in time.

A machine breaks down

The in-charge moves jobs to another line. She sees what slips and tells the counter.

End of shift

Quantities made are entered. The gap against plan is listed with a reason.

Who touches it

The people who open this every day.

Production in-charge

Lays out the day or the week and adjusts it when a machine stops.

Storekeeper

Sees what has to be ready before the shift starts, and what has to be bought. Nothing is a surprise.

Owner

Reads how much of the plan is being met, and where the same excuse keeps appearing.

How it is set up

From first conversation to daily use.

  1. Map the floor

    Walk us through machines, ovens or lines and the shifts they run. A written map of capacity comes back.

  2. List standing items

    Tell us which items repeat daily. A set of standing quantities is returned for approval.

  3. Link orders and stock

    Sales orders and stock arrive from your existing records. A trial plan appears for a sample day.

  4. Run beside the board

    Overlap for a while. The floor uses the screen while the whiteboard stays up, and differences are noted.

Measuring it

How you would know it is working.

Record where you stand before it goes live, so the change is measured against your own figures.

  • Planned quantity against quantity made, by item
  • Jobs that missed plan, with the stated reason
  • Shortages found before the run, against on the day
  • Machine or oven use against stated capacity
  • Plan changes after confirmation, by cause
How it fits

It is one part of a system, not an island.

A module earns its place by what it passes to the next one. These are the connections we set up most often.

  • Bill of materials
  • Work orders
  • Stock
  • Purchase orders
  • Sales orders
Common questions

Questions owners ask about production planning.

Do you have this already built somewhere?

Yes, in our Bakery Management System, where the daily bake plan is built from confirmed cake and bulk orders together with the usual counter quantities. For other trades it is fitted to your own units and shifts.

Is planning worth it when we make only to order?

It is, though in a simpler version. Make-to-order shops mostly need the sequence and the material call, and not a forecast. Start with the shortage list and leave the rest.

Is a diary still enough?

If one person plans and that person is always there, a diary works. It stops working when he is on leave, or when three customers are told the same Thursday. Both are risks.

Where does the stock figure come from?

From your own stock records, or from your accounting software where the store is kept there. The plan reads the balance and does not ask anyone to type it in twice.

What moves the cost of production planning?

Floor complexity does. Machines, lines, shifts, and the connections with stock, work orders, sales orders and bills of materials all count. Shortage alerts can be added after the plan screen works.

What decides how soon a plan can be run from it?

Clean item and capacity data. The starter scope holds the plan screen, standing quantities, shortage view and planned-against-made record. You hand over capacities and recipes, and the proposal fixes dates.

Talk to us

Tell us how you handle production planning today.

A spreadsheet, a register or another system: say which, and we will tell you plainly what is worth changing.

What happens after you share your requirements

  1. A senior engineer reads your answers. Nobody phones first.
  2. Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
  3. If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
  4. No call is booked and nothing is paid until you have read the note. Your details stay with us.

Start with your requirements

Seven short steps that tell us what you need. A senior engineer reads them before anyone gets in touch.

Share your requirements