… and how to avoid them

In many production companies planners often still rely on Excel to create production schedules. ERP and MRP systems often prove to be too inflexible to create a daily production schedule. Excel offers a user-friendly interface and a wide range of features, making it seem like a logical choice at first glance. However, when it comes to managing complex scheduling processes, Excel often falls short. In this blog, we discuss why Excel is not the ideal tool for production planning and how Advanced Planning & Scheduling (APS) software can provide a better solution.

Pitfall 1: Manual Errors – The Enemy of Accuracy

One of the biggest disadvantages of using Excel for production planning is its vulnerability to manual errors. Planning in Excel often requires entering data by hand, maintaining formulas and updating information regularly. Even a small typo can have major consequences, from missed deadlines to inefficient use of resources. Manual errors are not only difficult to detect, but also time-consuming to correct.

Pitfall 2: Limited Opportunities to Optimize

Excel is powerful for basic calculations and simple analysis, but it lacks the advanced optimization functions needed for efficient production planning. Production planners often must consider numerous variables such as available resources, working hours, machine capacity and delivery times. An APS system is specifically designed to address this complexity by using advanced algorithms to generate the most efficient schedules. This leads to better resource utilization, lower costs and shorter lead times.

Pitfall 3: Version control – Preventing Chaos

Another common problem with using Excel for production planning is managing multiple versions of a schedule. When multiple planners collaborate on a project, it is easy to create outdated or conflicting versions of a spreadsheet. This can lead to misunderstandings, duplication of effort and even errors in production. With APS software, version control is centralized, ensuring that everyone is always working with the most current and consistent data.

Pitfall 4: Real-time Information and Decision Making

A key advantage of APS software over Excel is its ability to process and analyze real-time information. In a dynamic manufacturing environment, it is essential to be able to react quickly to changes, such as delayed deliveries, machine downtime or last-minute changes in production demand. APS systems are designed to immediately process such changes and adjust scheduling accordingly. This enables planners to make faster and more accurate decisions, resulting in a smoother production process.

Pitfall 5: Integration with Other Systems

Modern APS solutions can integrate seamlessly with other business software such as ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems). These integrations ensure an uniform data flow throughout the company, reducing manual data entry and reducing the risk of errors. Excel, on the other hand, often requires manual data transfer between systems, which is time-consuming and error-prone.

Conclusion

While Excel is a versatile and powerful tool for many business applications, it is not the ideal choice for production planning. The manual nature of working with Excel, its limited optimization capabilities, the risk of multiple versions and the challenge of real-time information make it unsuitable for the complex needs of modern manufacturing environments. By switching to an advanced APS solution, companies can streamline their planning processes, increase efficiency and significantly reduce the risk of errors.

At Planwisely, we are dedicated to providing the most advanced and user-friendly scheduling solution. Contact us today to find out how our APS software can take your production planning to the next level.