{"id":13192,"date":"2026-06-08T23:50:41","date_gmt":"2026-06-08T23:50:41","guid":{"rendered":"https:\/\/8657085.xyz\/?p=13192"},"modified":"2026-06-08T23:50:41","modified_gmt":"2026-06-08T23:50:41","slug":"what-happens-when-production-planning-gets-too-big-for-spreadsheets","status":"publish","type":"post","link":"https:\/\/8657085.xyz\/?p=13192","title":{"rendered":"What happens when production planning gets too big for spreadsheets"},"content":{"rendered":"<p> <div style=\"display: grid; grid-template-columns: 300px 160px; gap: 2px; width: 460px; background: #eee; padding: 2px;\">\r\n\r\n  <!-- \u6574\u884c\u5bbd\u5e7f\u544a -->\r\n  <div style=\"grid-column: 1\/-1; width: 460px; height: 250px; background: #ccc; display: grid; place-items: center;\">\r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e2\" data-zoneid=\"5876674\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n  <\/div>\r\n  <div style=\"grid-column: 1\/-1; width: 460px; height: 90px; background: #ccc; display: grid; place-items: center;\">\r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e2\" data-zoneid=\"5876676\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n  <\/div>\r\n\r\n  <!-- \u5de6\u4fa7\u7ad6\u6392 -->\r\n  <div style=\"height: 250px; background: #ccc; display: grid; place-items: center;\">\r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e2\" data-zoneid=\"5876672\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n  <\/div>\r\n  <div style=\"height: 500px; background: #ccc; display: grid; place-items: center;\">\r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e2\" data-zoneid=\"5876680\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n  <\/div>\r\n\r\n  <!-- \u53f3\u4fa7\u6469\u5929\u697c\uff08\u548c\u5de6\u4fa7\u5b8c\u5168\u5bf9\u9f50\uff09 -->\r\n  <div style=\"grid-row: 3\/5; height: 750px; background: #ccc; display: grid; place-items: center;\">\r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e2\" data-zoneid=\"5876678\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n  <\/div>\r\n  \r\n  <script async type=\"application\/javascript\" src=\"https:\/\/a.magsrv.com\/ad-provider.js\"><\/script> \r\n <ins class=\"eas6a97888e6\" data-zoneid=\"5876682\"><\/ins> \r\n <script>(AdProvider = window.AdProvider || []).push({\"serve\": {}});<\/script>\r\n<\/div><br \/>\n<\/p>\n<div style=\"padding-right:0;padding-left:0\">\n<p class=\"wp-block-paragraph\">Matthew Sabourin built his own production scheduling system before he ever thought about buying one.<\/p>\n<p class=\"wp-block-paragraph\">He pulled it together with his intuition, spreadsheets, and years spent waiting for beer to ferment at Nonsuch Brewing Co., a majority Indigenous-owned craft brewery in Winnipeg\u2019s Exchange District. It had an intelligence to it, but the whole system lived in Sabourin\u2019s head, and when the brewery needed him elsewhere, it seized up.<\/p>\n<p class=\"wp-block-paragraph\">\u201cIt got so onerous to me, we had to shelve the tool,\u201d says Sabourin, president and co-founder of Nonsuch. \u201cWe just stopped using it, because I needed to be other places.\u201d<\/p>\n<p class=\"wp-block-paragraph\">Most companies have one. The spreadsheet that started out as a quick fix that became a system, which then turned into a small hostage situation.<\/p>\n<p class=\"wp-block-paragraph\">An industry friend saw what Sabourin had built, and told him he needed to talk to Cameron Bergen, founder and CEO of Mode40, a Steinbach, Manitoba-based enterprise data intelligence firm.<\/p>\n<p class=\"wp-block-paragraph\">The two joined a Canadian Food Innovation Network webinar on May 28, moderated by <em>Digital Journal<\/em>, to walk through how they\u2019re solving it.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">Nonsuch isn\u2019t alone in this. In manufacturing. When operational knowledge lives in one person, the cost shows up on the production floor as capacity you didn\u2019t know you were losing.<\/p>\n<p class=\"wp-block-paragraph\">Capital expenditures across Canada\u2019s food and beverage sector declined 5.3% in 2025, according to Farm Credit Canada (FCC), and early indicators suggest investment could weaken further in 2026. The sector is also short 50,000 workers, according to the Canadian Agricultural Human Resource Council.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">For most of the sector\u2019s 11,000-plus businesses, that starts with the operations they already have. Unfortunately, some of it\u2019s hiding inside a spreadsheet named \u201cFinal_FINAL_revised_v7.\u201d\u00a0<\/p>\n<p class=\"wp-block-paragraph\"><em>If you\u2019re lucky<\/em>, it\u2019s marked with a date or someone\u2019s initials.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">Nonsuch and Mode40\u2019s partnership is a working example of what it takes to bring AI onto a small manufacturer\u2019s floor, including the messy data, the buy-in, and the slow build.<\/p>\n<h2 id=\"h-small-operations-carry-billion-dollar-complexity\" class=\"wp-block-heading\">Small operations carry billion-dollar complexity<\/h2>\n<p class=\"wp-block-paragraph\">Beer sounds simple when you\u2019re the one ordering it at the bar. But behind the scenes, the customer wants it tomorrow, the tank needs three more days, and the production spreadsheet starts feeling more like you\u2019re painting while blindfolded.<\/p>\n<p class=\"wp-block-paragraph\">Bergen has solved this kind of problem at larger facilities. Nonsuch packs it into a fraction of the space.<\/p>\n<p class=\"wp-block-paragraph\">\u201cIt\u2019s probably one of the hardest production scheduling calculations that we\u2019ve seen, even across multibillion-dollar enterprises,\u201d he says.<\/p>\n<p class=\"wp-block-paragraph\">You can\u2019t tell a batch of beer when to finish fermenting. One extra day in the tank cascades through the entire plan.<\/p>\n<p class=\"wp-block-paragraph\">\u201cWhy not just make big batches of everything and leave this on the shelf forever, right?\u201d Bergen says. \u201cBecause quality is too important to what they do.\u201d<\/p>\n<p class=\"wp-block-paragraph\">The underlying problem is familiar to any operation with unpredictable outputs and customer demands that arrive faster than production can respond.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">At Nonsuch, the variable is biology. We\u2019re talking about yeast and the environment required to do its job. It\u2019s done when it\u2019s done.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">Elsewhere it might be supply chain delays, machine variability, or shifting customer specifications. The details change, but the headache is familiar.<\/p>\n<p class=\"wp-block-paragraph\">Mode40\u2019s system creates a digital model of the brewery\u2019s production process, then uses Nonsuch\u2019s own rules around quality, capacity, and customer commitments to help schedule what should be brewed, packaged, and prioritized.<\/p>\n<p class=\"wp-block-paragraph\">Before Mode40, Sabourin managed all of it across multiple manually updated spreadsheets. One beer might need to be packaged into different keg sizes and can formats, while multiple batches sit at different stages of fermentation, and orders arrive the same day they need to ship.<\/p>\n<p class=\"wp-block-paragraph\">\u201cI built a spreadsheet that is populated manually, updated again and again and again manually, [and] prone to human mistake,\u201d says Sabourin.<\/p>\n<p class=\"wp-block-paragraph\">Unfortunately, every missed production window compounds.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">\u201cOnce that opportunity is gone, you can\u2019t get it back,\u201d he adds. \u201cIt\u2019s gone forever.\u201d<\/p>\n<p class=\"wp-block-paragraph\">One of the less glamorous problems was getting the data out in the first place. Sabourin says Nonsuch\u2019s enterprise resource planning (ERP) didn\u2019t have an export button, so Mode40\u2019s team pulled the information from the webpage code instead.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">It doesn\u2019t get more small manufacturer-coded than \u201cthe data exists, technically, but good luck retrieving it.\u201d<\/p>\n<h2 id=\"h-ai-can-t-fix-what-it-can-t-see\" class=\"wp-block-heading\">AI can\u2019t fix what it can\u2019t see<\/h2>\n<p class=\"wp-block-paragraph\">Bergen starts every consultation on site, because what a manufacturer describes on a call and what he finds on the floor are almost always different problems.<\/p>\n<p class=\"wp-block-paragraph\">\u201cIf you haven\u2019t seen it, don\u2019t try to scope it,\u201d he says.<\/p>\n<p class=\"wp-block-paragraph\">Mode40 builds a digital model of the facility first, then layers the operator\u2019s decision rules on top. When two orders need the same tank on the same day, what wins? The bigger customer, the tighter margin, the beer that can\u2019t wait?<\/p>\n<p class=\"wp-block-paragraph\">\u201cYou\u2019re really going to answer them,\u201d Bergen says. \u201cThose sets of rules become the foundational barriers to the way the system works.\u201d<\/p>\n<p class=\"wp-block-paragraph\">Without that foundation, even advanced AI will produce outputs that look right on screen and fall apart on the floor.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">This goes well beyond food and beverage. Implementing AI before mapping the operation is how companies end up with a confident answer to the wrong problem.<\/p>\n<p class=\"wp-block-paragraph\">The Nonsuch-Mode40 partnership is ongoing, with sales forecasting work still in progress. Bergen says one of the early opportunities is making capacity issues visible before they become missed orders.<\/p>\n<p class=\"wp-block-paragraph\">He says the goal is to spot conflicts early enough that manufacturers can adjust production or call clients before a missed order becomes a relationship problem.<\/p>\n<p class=\"wp-block-paragraph\">\u201cYou\u2019ve mitigated the risk ahead of time without ticking off a client,\u201d says Bergen.<\/p>\n<h2 id=\"h-nobody-wants-another-screen-to-babysit\" class=\"wp-block-heading\">Nobody wants another screen to babysit<\/h2>\n<p class=\"wp-block-paragraph\">Sabourin came into the implementation process more technically confident than most, having built his own platform in a previous business. Even so, his employees had questions about the six different systems they had stitched together.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">\u201cWithout full buy-in, you\u2019re going to be struggling uphill the entire time,\u201d he says. \u201cSo you need everybody to believe that this is the right solution, so that they can be a partner in the implementation rather than resistance.\u201d<\/p>\n<p class=\"wp-block-paragraph\">Fair enough. Most workers have met at least one system that was supposed to save time and somehow created a new part-time job.<\/p>\n<p class=\"wp-block-paragraph\">Mode40 runs facilitation sessions before implementation starts to surface concerns early, everything from data privacy to scars from legacy systems that promised more than they delivered. Bergen says most of those fears come from how technology used to be sold.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">\u201cThe more complicated it is in that fashion, [the more] likely they\u2019re selling you on the idea,\u201d he says.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">Modern tools should be harder to explain than they are to use. Bergen\u2019s read is that when a platform overwhelms you with screens and features, you\u2019re paying for the complexity, not the results.<\/p>\n<p class=\"wp-block-paragraph\">For Sabourin, the payoff is the physical plant. Nonsuch has a fixed number of tanks and a fixed amount of floor space, and the goal is squeezing more out of both.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">\u201cThe more we can get out of it, the better,\u201d he says.<\/p>\n<p class=\"wp-block-paragraph\">A new FCC report found that hitting 3% annual GDP growth in Canadian food and beverage manufacturing over the next decade could add $40 billion to the national economy and create 217,000 jobs.\u00a0<\/p>\n<p class=\"wp-block-paragraph\">For the SMEs that make up most of the sector, that kind of growth starts the way it did at Nonsuch, by getting more out of what\u2019s already on the floor.<\/p>\n<h2 id=\"h-final-shots\" class=\"wp-block-heading\">Final shots<\/h2>\n<ul class=\"wp-block-list\">\n<li>Many manufacturers are running on institutional knowledge trapped in one person and forecasting spread across disconnected systems.<\/li>\n<li>If an AI platform can\u2019t map how your operation works before it starts automating, the outputs will likely be wrong, despite sounding confident.<\/li>\n<li>When evaluating new tools, Bergen\u2019s test is whether the architecture lets you start with one problem and grow from there.<\/li>\n<\/ul>\n<p class=\"wp-block-paragraph\"><strong><em>Watch the full webinar, moderated by Digital Journal, below:<\/em><\/strong><\/p>\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\">\n<p>\n<iframe title=\"Tech Adoption in Action Mode40 and Nonsuch Brewing\" width=\"640\" height=\"360\" src=\"https:\/\/www.youtube.com\/embed\/zi98Z1vwYxE?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/p>\n<\/figure>\n<\/div>\n<p><!-- \u603b\u5bb9\u5668\uff1a\u6700\u5927\u5bbd908px Grid\u7d27\u51d1\u5e03\u5c40 -->\r\n<div style=\"display: grid; grid-template-columns: 728px 160px; gap:2px; width:908px; background:#eee; padding:2px;\">\r\n\r\n  <!-- \u901a\u680f\u9876\u90e8\uff1a\u6700\u5927\u6a2a\u5e45 908x258 \u8de8\u6574\u884c -->\r\n  <div style=\"grid-column:1\/-1; height:258px; background:#ff6b6b; display:grid; place-items:center;\">\r\n    <!-- JuicyAds v3.0 -->\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async src=\"https:\/\/poweredby.jads.co\/js\/jads.js\"><\/script>\r\n<ins id=\"1114307\" data-width=\"908\" data-height=\"258\"><\/ins>\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async>(adsbyjuicy = window.adsbyjuicy || []).push({'adzone':1114307});<\/script>\r\n<!--JuicyAds END-->\r\n  <\/div>\r\n\r\n  <!-- \u7b2c\u4e8c\u901a\u680f\uff1a728\u00d790 \u901a\u680f -->\r\n  <div style=\"grid-column:1\/-1; 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display:grid; place-items:center;\">\r\n\t<!-- JuicyAds v3.0 -->\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async src=\"https:\/\/poweredby.jads.co\/js\/jads.js\"><\/script>\r\n<ins id=\"1114302\" data-width=\"133\" data-height=\"139\"><\/ins>\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async>(adsbyjuicy = window.adsbyjuicy || []).push({'adzone':1114302});<\/script>\r\n<!--JuicyAds END-->\r\n\t<\/div>\r\n    <div style=\"height:125px; background:#91e7ac; display:grid; place-items:center;\">\r\n\t\r\n<!-- JuicyAds v3.0 -->\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async src=\"https:\/\/poweredby.jads.co\/js\/jads.js\"><\/script>\r\n<ins id=\"1114303\" data-width=\"125\" data-height=\"125\"><\/ins>\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async>(adsbyjuicy = window.adsbyjuicy || []).push({'adzone':1114303});<\/script>\r\n<!--JuicyAds END-->\r\n\t<\/div>\r\n  <\/div>\r\n\r\n  <!-- \u53f3\u4fa7\u7ad6\u680f\uff1a160\u00d7600 \u6574\u5217\u9ad8\u5e7f\u544a -->\r\n  <div style=\"grid-row:3\/8; height:600px;  display:grid; place-items:center;\">\r\n    <!-- JuicyAds v3.0 -->\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async src=\"https:\/\/poweredby.jads.co\/js\/jads.js\"><\/script>\r\n<ins id=\"1114301\" data-width=\"160\" data-height=\"600\"><\/ins>\r\n<script type=\"text\/javascript\" data-cfasync=\"false\" async>(adsbyjuicy = window.adsbyjuicy || []).push({'adzone':1114301});<\/script>\r\n<!--JuicyAds END-->\r\n  <\/div>\r\n\r\n<\/div><br \/>\n<br \/> What happens when production planning gets too big for spreadsheets<br \/>\n<br \/>#production #planning #big #spreadsheets<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Matthew Sabourin built his own production scheduling system before he ever thought about buying one&#8230;.<\/p>\n","protected":false},"author":1,"featured_media":13193,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[7],"tags":[152,79,145,12154],"class_list":["post-13192","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-stories","tag-big","tag-planning","tag-production","tag-spreadsheets"],"featured_image_urls":{"full":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3.png",1600,900,false],"thumbnail":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-150x150.png",150,150,true],"medium":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-300x169.png",300,169,true],"medium_large":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-768x432.png",640,360,true],"large":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-1024x576.png",640,360,true],"1536x1536":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-1536x864.png",1536,864,true],"2048x2048":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3.png",1600,900,false],"covernews-slider-full":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-1115x715.png",1115,715,true],"covernews-slider-center":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-800x500.png",800,500,true],"covernews-featured":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-1024x576.png",1024,576,true],"covernews-medium":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-540x340.png",540,340,true],"covernews-medium-square":["https:\/\/8657085.xyz\/wp-content\/uploads\/2026\/06\/TechTO-3-400x250.png",400,250,true]},"author_info":{"display_name":"admin","author_link":"https:\/\/8657085.xyz\/?author=1"},"category_info":"<a href=\"https:\/\/8657085.xyz\/?cat=7\" rel=\"category\">Stories<\/a>","tag_info":"Stories","comment_count":"0","_links":{"self":[{"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/posts\/13192","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/8657085.xyz\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=13192"}],"version-history":[{"count":0,"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/posts\/13192\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/8657085.xyz\/index.php?rest_route=\/wp\/v2\/media\/13193"}],"wp:attachment":[{"href":"https:\/\/8657085.xyz\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=13192"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/8657085.xyz\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=13192"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/8657085.xyz\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=13192"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}