IPCIntegrated Planning & Control
An operating system for steering a supply chain

How a supply chain is actually steered

Six principles. A twelve step planning process, from the supply model through S&OP, MPS, MRP and capacity planning to the shop floor. And the operating model around it: systems, policies, roles, measurement and proof. Select anything to open its definition, a worked example and a question to test yourself against.

Layer 1 · Principles

the behavioural base

Layer 2 · The planning process

design, tactical, execution

Layer 3 · The operating model

systems, policies, people, proof
Guided sequence

Twenty steps, in dependency order

This is not the order the process runs in. It is the order the model is easiest to learn in: start with the outcome, then what controls it, then what has to be true first, then the machinery.

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Four simulations

Move the input, watch the system answer

Each model is illustrative and deliberately simple. The point is the direction and the shape of the response, not a forecast of your own numbers.

How far ahead of the requested delivery the change reaches planning.
As a share of the monthly plan volume for the family.
Longest procurement path through to finished goods. Sets the planning fence.
The execution window in which the schedule is committed.
Where the change lands
Planning horizon, counted backwards from the requested delivery date
Applied cumulatively across the twelve month horizon.
From the routing. Recalibrate from demonstrated performance, not the engineering estimate.
Real conditions versus standard: changeovers, deviations, cleaning.
What the resource has actually produced, not what is installed.
Two weeks of the month unavailable.
Planned load ratio by month
Planned load ÷ demonstrated capacity. Above 100% the plan is not executable as it stands.
Feasible, under 85% Tight, 85 to 100% Infeasible, over 100% Demonstrated capacity
Show the numbers
How often the released schedule is executed as planned.
Expediting, buffers and heroics that catch failures before the customer sees them. The lever most organisations pull instead of fixing the cause.
How a data defect becomes a service failure
Illustrative propagation model. Direction and shape, not your numbers.

Definitions

The working vocabulary

The working vocabulary of planning and control, as practitioners use it. Where a term is contested, the entry says which reading is used here and why it matters.

Thirty two metrics

What each KPI measures, and how it is counted

These are diagnostic instruments. Each entry gives the definition, how it is counted, and the thing that most often makes the number lie. Read the set as a stack: master data feeds plan performance, plan performance feeds execution, and execution feeds customer service.

Working definitions. Calculation rules, tolerances and targets are organisation specific, so verify each against your own metrics handbook before using it in a review. Targets are deliberately not printed here: a threshold that is right for a stable make to stock network is wrong for a constrained launch portfolio, and a number carried over from someone else's scorecard is the fastest way to make a metric meaningless.
Eight patterns

It rarely fails through missing documents

It fails through design decisions nobody was asked to make, or made once and never revisited. Each pattern breaks one of the six principles, which is what lets you diagnose it rather than just regret it.

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