FAILURE: Capacity plans become mathematically correct and operationally wrong when constraints are stale

Current planning signals emphasize plan-for-every-part, production capacity, maintenance optimization and constraint-based planning. These systems remain exposed when labor, maintenance, tooling, material or yield assumptions are not refreshed and owned.

Why it matters

A planning engine can optimize only the constraints it receives. Stale assumptions can produce a technically valid plan that cannot be executed.

What leaders should monitor

• parameter age and effective dates;
• named owners for capacity constraints;
• modeled versus demonstrated capacity;
• manual overrides and local calendars;
• maintenance and tooling changes not reflected in APS or ERP.

Sources: Caterpillar and DecisionBrain.