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PPS system - production planning and control system

PPS system - production planning and control system


The modern manufacturing industry is facing growing challenges that require more precise planning, more efficient control and continuous optimization. A key tool in this context is the production planning and control system, or PPS for short. This specialized software is the linchpin that supports companies in mastering the complex balance of resources, capacities and time-critical processes.

But what exactly is behind this PPS system? How does it effectively shape the production landscape and why is it indispensable for companies? Let's delve into the world of PPC systems together to find the answers and explore the important role they play in modern manufacturing. Welcome to a journey through the key components, features and benefits that PPC systems bring to operational reality.



What is a PPS system?

A production planning and control system, or PPS for short, is a specialized software tool used in the manufacturing industry to enable and optimize the planning, control and monitoring of production processes. The PPS software serves as the central hub for the entire production planning and control process, while also allowing users to efficiently manage and analyze data.

With the help of a PPS system, production, purchasing and sales professionals can make precise and data-based decisions. This includes the precise planning of production processes, the optimization of capacities and resources, as well as the strategic control of material procurement and sales processes.

By analyzing real-time data, the PPS system enables well-founded decisions to be made regarding unexpected events and their impact on plan changes, costs and delivery times. In this way, it makes a significant contribution to increasing the efficiency and competitiveness of the company. PSS systems are an important tool for making optimal decisions based on objective real-time data.

Depending on the type of production, i.e. make-to-order production or series or mass production, the approach or mode of operation of a PPS system differs fundamentally. This must be taken into account when selecting and evaluating a provider of PPS systems in order to avoid costly bad investments!


The function of a PPS system


Efficient planning: A production planning system enables precise planning of production processes, capacities and resources.

Transparency and control: Only the integration of PPS and MES software ensures that production plans are implemented operationally efficiently and that unexpected events can be responded to effectively.

Cost control: Better planning and control of production enables companies to minimize their costs.

Increased productivity: The integration of PPS, MES and ERP software improves production processes and minimizes throughput times.

Higher quality: Product quality is improved through more precise control and monitoring of machines and processes.

Just-in-time strategy: With a PPS system, companies can adapt production to customer requirements and pursue a just-in-time strategy.



The interaction of MES and PPS systems in the modern production environment

A production planning system (PPC) plays a decisive role in the planning, control and optimization of production processes. At the heart of this system are primarily the production planning tasks and functions that aim to make production processes more efficient.

A good plan quickly becomes a waste of time if it is not constantly compared with reality in production! This is where the Manufacturing Execution System (MES) comes into play: it is a specialized IT system that provides real-time data from production - from machine data and order data to quality data - and enables planned orders to be executed, processed and reported back at store floor level. The PPS system uses this actual data to transparently display the execution and status of planned orders and to continuously improve production processes.

The significant advantage of a PPS/MES integration is that a production plan is not only an optimal "beautiful" plan, but also has a real chance of being implemented in cooperation with the planner.  Thanks to the constant flow of data provided by the MES, the PPS can ensure that production plans are adhered to precisely, which in turn optimizes the use of resources, delivery readiness and customer satisfaction.




Symbiosis: PPS- MES- ERP systems

However, it is not only the PPS that benefits from the data of the MES system. An ERP (Enterprise Resource Planning) system, whose definition focuses on the holistic support of all core business processes of a company, can also make use of this information. The PPS sometimes serves as a bridge between MES and ERP, allowing the ERP system to support more precise and timely decisions throughout the company.



Where are PPS Systems used?

A production planning system is recommended by experts to map the complexity of the production process. They help with the planning of production processes in the company, inventories and the control of delivery times. The software enables planners to precisely determine material and capacity requirements.

Examples and applications:

To illustrate the versatile application of PPS systems in the real world, let's look at the example of a car manufacturer. Here, a high-performance PPS system enables the precise planning of production processes, from the ordering of raw materials to the delivery of finished vehicles. By integrating real-time data on machine capacities and production progress, production managers can react quickly to bottlenecks and ensure the optimal use of resources.

Another application example can be found in the food industry. Here, a PPS system supports the management of production processes from the procurement of raw materials to packaging and distribution. It enables the precise coordination of stock levels to ensure that fresh products are produced and delivered at the right time. This efficient planning not only reduces waste, but also promotes compliance with quality standards and delivery deadlines.

In the electronics industry, PPS systems play a key role in adapting to rapidly changing market requirements. By continuously monitoring changes in demand, manufacturers can flexibly adapt their production plans to respond to trends and customer needs. This enables a faster market launch of new products and strengthens the company's competitive position.

Another application example can be found in the field of pharmaceutical production. Here, PPS systems play a decisive role in the management of production processes, from the procurement of raw materials to the packaging of medicines. Precise planning not only ensures efficient use of resources, but also guarantees compliance with strict quality standards.

These examples illustrate how PPS systems in different industries help to optimize complex production processes, minimize costs and increase flexibility in a dynamic market environment. By integrating PPS systems, companies can not only increase their efficiency, but also maintain their competitiveness and successfully meet the changing demands of the market.

The most modern approaches of Industry 4.0:
  • SaaS tools for the entire production and your PPS 
  • get started immediately, without the usual investment costs
  • Transparency and key figures without personnel deployment in real time
  • Enabling a reduction in operating costs in just a few days
  • Improve collaboration and increase productivity
  • Improving quality and reducing waste
  • Faster decision-making based on objective data
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PPS systems in the management of production processes

A PPS system is a versatile tool for planning and organizing production processes. It helps companies to make the right decisions regarding materials, capacities and ultimately order planning. The software solutions available on the market address the different requirements of manufacturing companies. When selecting a PPS, attention must be paid to the specific features depending on the type of production, i.e. make-to-order production or series or mass production. In addition to the traditional on-premises PPS systems, a few providers now offer modern, quickly available and cost-efficient PPS systems as cloud-native products, i.e. as Software-as-a-Service (SaaS).

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Production processes can be simple, but they can also be extremely complex. PPS systems are designed to map complex processes and order networks in order to help companies maintain an overview. They offer a digital representation of all production processes and create transparency in real time, which ultimately makes it possible to use resources efficiently, effectively, cost-effectively and on time.

PPS systems digitize complex planning processes that traditionally exist mainly in the heads of a few experts in logistics and work preparation. Only digital tools simplify the planning of complex processes and enable structured and efficient optimization.




The role of PPS systems in day-to-day operations

PPS systems play a central role in the day-to-day operations of complex procurement and production processes. They support planners in managing inventories, planning orders, controlling production and procurement processes and ensuring on-time delivery.

Material requirements planning (MRP) is of central importance here. Material requirements planning determines the materials and components required to manufacture a product. It consists of three main steps: Inventory of existing materials and components, determination of additional materials and components required and planning of production or purchasing.

Depending on the provider, MRP functionalities can be found in both ERP and PPC systems. Only one of the two system levels can sensibly take on the important MRP task in day-to-day operations. Sufficient specialist knowledge is required for this essential decision! External consultants support the successful implementation of a PPS project, which usually takes several weeks, and align it to the specific requirements of a company.


The possible applications of PPS systems in production processes

There are many ways in which PPS systems can be used in production processes. Thanks to their integration capability, PPS systems can be incorporated into the production process in a wide variety of ways. Their wide range of applications extends from the planning and control of basic processes to the coordination of all steps, from the procurement of materials to the completion of products.

Depending on the flexibility of a PPS system, optimal integration into the existing IT architecture is possible, so that a customized tool is available that is precisely tailored to your specific requirements and work processes. PPS systems should play a crucial role in creating a seamless, efficient and well-coordinated production process.



PPS systems and their significance for users

The use of PPS systems provides users with a multifaceted relief in their everyday work. This software not only enables precise planning and control of production processes, but also acts as a tool to provide a clear overview of the current status of production. This not only creates transparency, but also enables everyone involved to be well informed at all times and to understand their tasks in the context of the overall process. This increased availability of information helps users to work more effectively and in a more targeted manner.

In addition, PPS systems enable bottlenecks to be identified more quickly so that a proactive response can be made. Overall, the integration of PPS systems means a considerable increase in efficiency for users and an improved quality of work in their daily routine.



PPS systems and the support of product development

PPS systems are not just limited to ongoing production. They can also be an important issue in product development. The software supports the planning of production processes as early as the design phase, which helps to develop more efficient products with exciting features.

Controlling costs and inventory is a crucial task in any business. PPS systems offer comprehensive ways to minimize costs and manage inventory efficiently. This helps to increase a company's competitiveness.

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A PPS system can be an important building block for a manufacturing company on the way to efficient production planning and control. Apart from the primary planning tasks, more precise cost control through to continuous process improvement can provide further benefits to successfully meet the growing challenges of modern industry. The integration of PPS systems is not only a strategic decision for the present, but also for the future, in order to adapt flexibly to the dynamics of the market.

With its manufacturing platform and modern Software-as-a-Service (SaaS), SYMESTIC makes it possible to provide the digital real-time database from the store floor in no time at all. This is the fastest, easiest and most cost-effective way to create the conditions for the sensible use of a PPS system!

Without knowledge of the actual situation in terms of plant, operator, tool or material availability, etc., any planning is built on very thin ice. Only by constantly comparing a plan (target) with the constantly changing actual conditions on the store floor can deviations and problems be detected at an early stage. The planner receives important information (notifications) and data (actual quantity, rejects, occupancy, etc.) on his plan data as an important basis for decision-making in order to be able to initiate the optimum measure immediately. Apart from the positive cost and deadline aspects, this leads to significantly less stress and more satisfaction for everyone involved.

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