The reality in repetitive shops is that multiple batches of a limited number of parts are manufactured repeatedly. This makes it imperative that repetitive shops are managed on Part Numbers and not on Order Number. In fact manufacturing planning, manufacturing progress reporting and Work in Process reporting are all done on Part Numbers. This makes traditional Advanced Planning and Scheduling systems, available in the market currently, ineffective for repetitive manufacture.

The other unique feature of repetitive manufacture is the use of same common part across multiple products. This makes Order based pegging feature of APS unsuitable in repetitive environment. Currently available Advanced Planning and Scheduling Systems fix the relationship between the works/purchase orders during the Bill of Material explosion or during the download from the MRP system. The drawback of this is that if there is some change in production rate of final product or change in demand of final products or some unexpected production constraint, you cannot dynamically reallocate common parts across different products.

FDS has built a specific algorithm for planning/scheduling of repetitive shops. This algorithm combines the best features of APS and Lean Planning. It considers finite availability of machine, manpower and tool resources and at the same time plans/schedules on Part Numbers and ensures constant re-allocation of common shortage parts based on the changing shop floor reality.

This algorithm considers demands for individual Parts, production rates of individual machines, current buffer status (both at Stores and in process buffers), manpower/tool constraint and WIP to ensure that individual Parts are scheduled so as to minimize in process inventory and to meet demands for different product lines.