The Benefits and Capabilities of Production Planning Simulations

For managers who are considering a change in their manufacturing facility, simulating the proposed improvements has been a standard practice for years. While basic simulations can involve getting a few interns to act out the part of new machinery while someone times the process with a stopwatch, many companies require more sophisticated modeling programs.

In many cases, modeling is included as one of the features on APS software packages. These programs are able to test out new ideas in order processing, maintenance schedules, equipment and personnel positioning, and even factory layout, without actually moving a single piece of equipment. They are based on metrics for accurate, fact-based decision making.

Simulations are a vital part of production planning for any modern production facility. While an experienced manager certainly knows enough about his or her factory to create an efficient production schedule and deal with changes as they come up, it’s necessary to have a reliable way to solve problems, test new ideas and establish priorities without a large investment.

Setting a Maintenance Schedule 

Often, these changes are not large-scale improvements. While it’s certainly possible to use APS software to determine the optimal location for a new production facility or the best way to redesign a production pod, day to day production planning tends to focus on smaller issues.

Setting a maintenance schedule is a prime example of how APS software can use simulations to optimize a manufacturing facility. While managers are capable of making up a good maintenance schedule without the help of software, most realize that there are several factors that can create problems throughout an entire facility. For example, a sudden rush order can throw off a carefully crafted maintenance schedule as technicians are diverted from scheduled work to prepare a line for an overrun. Any maintenance that was planned for the line has to be delayed, potentially creating problems throughout the whole factory.

Advanced Planning & Scheduling Plant Simulations

APS software, however, can devise several different maintenance schedules that simulate what needs to be done in the event of a rush order, sudden mechanical failure, or even a staff shortage. Instead of management spending hours creating reactive contingency plans, production planning software can take a well-planned maintenance schedule and quickly modify it to fit a number of scenarios. With the right data, the APS system can even create the original maintenance schedule.

For production managers, these simulations provide a much-needed alternative plan for the hundreds of unexpected things that can go wrong in a factory. Simulations can also give a manager the information that he or she needs to make decisions about a facility’s future. Using APS software to show the effects of different worker schedules, for example, is a simple way to test out new shift arrangements or leave policies without upsetting employees. Building a simulation to include an additional front or back end production line can allow a manager to see if increasing production capacity would really create more product or just move a limiting factor to another area of the production facility.

Using What-If Scenarios in Production Planning Simulations

See how what-if scenarios make production planning simulations practical for day-to-day decisions. In this video, PlanetTogether APS is used to build and compare multiple production planning scenarios—changing maintenance windows, shift patterns, routings, and capacity—to see the impact on throughput, bottlenecks, and delivery performance before anything is changed on the shop floor. It is an ideal next step if you want to move beyond static plans and use simulations to support smarter, data-driven decisions in your manufacturing facility.

 

Ready to Turn Simulations into a Real APS Implementation?

In this article, you’ve seen how production planning simulations can help you test new ideas—maintenance schedules, equipment moves, worker schedules, and capacity changes—without risking disruption or investing in the wrong improvements. You’ve also seen that many of these simulation capabilities are built directly into modern Advanced Planning and Scheduling (APS) software like PlanetTogether, allowing managers to compare multiple scenarios and choose the best plan for throughput and reliability.

The next step is understanding what it actually takes to implement APS so your team can use simulations and what-if scenarios as part of everyday planning.

Our white paper, “APS Implementation: Just the Facts,” gives you a clear, practical roadmap from initial evaluation through go-live. It explains how to use your existing ERP/MRP data, how integration works, who needs to be involved, and what to expect at each stage of an APS project.

In this guide, you’ll learn how to:

• Turn current ERP/MRP data (orders, routings, BOMs, capacities) into a robust APS model that supports what-if simulations
• Plan integration so optimized, simulation-tested schedules flow back to your ERP and shop floor systems
• Set realistic expectations for APS project scope, timeline, and internal resource requirements
• Define roles for operations, planning, IT, and your APS provider so simulations actually lead to better decisions—not just interesting reports
• Ensure APS delivers what simulations promise: higher throughput, fewer bottlenecks, better use of maintenance windows, and more confidence in your planning decisions

If you’re ready to move from “talking about simulations” to running them in a live APS environment, this guide is your next step.