Preactor and Lean Scheduling

Preactor for Planning and Scheduling | Finite Capacity Scheduling Demand Driven Lean


The Lean Problem

The inability of ERP systems to support Lean initiatives has led Lean practitioners to rely almost exclusively on simple, visual control systems.

However, the Aberdeen Group concludes that “Many manufacturers have taken some of Lean’s principles such as simplification too far and are missing critical benefits that software and technology can bring in systematizing and sustaining Lean methods in the organization.”

Lean is unable to work effectively when faced with variable demand patterns and complex value streams.

Like ERP, Lean is unable to handle change!


Lean has always focused on improving internal processes.

Lean relies on Kanban to connect to customer demand.

Kanban has the following seven major limitations.

  1. Too Slow
  2. Too Rigid 
  3. Unable to Accurately Prioritize Upstream Demand 
  4. Unable to Intelligently Sequence Upstream Work 
  5. Only Communicates in One Direction (no Cause & Effect)
  6. Unable to Simulate Alternate Solutions
  7. Can Create Unnecessary Buffers

The Lean Solution

Build on Lean’s success by replacing obsolete core ERP planning functionality with new and innovative APS tools that support Lean’s strengths while adding critical functionality that enables manufacturers to:

  • React quickly and systematically to variable demand patterns
  • Accurately synchronize level loaded production schedules with the flow of material
  • Eliminate non-value-added activities needed just to maintain ERP
  • Extend Visual Control Systems to provide company-wide visibility
  • Make better operational decisions by simulating the consequences of what-if alternatives

Read the following articles to find out more about Preactor and Demand Driven Lean: