Effective Production Planning, Scheduling & Control

Planning and Control Technique for More Effective Production Operations

The costs of neglecting up-to-date production operations are enormous - miserable productivity, wasted man-hours, lost productions, machine downtime and strained relations with your customers. Shutdowns are costly. More frustrating are unexpected shutdowns caused by planning mistakes. Planning is the heart of manufacturing. It determines your success in satisfying your customers, which in turns determines your company performance.

Successful manufacturing planning and control is the vital link to your plant’s continued efficiency and productivity. The amount of money invested is also substantial and this investment will directly affect the profitability of your operations. Therefore it is fundamental to update and improve your production system to ensure you derive maximum benefits, your plant is well geared up and in excellent operating condition as well as your employees are working at top effectiveness.

This practical and intensive course offers a realistic discussion of increasing efficiency and productivity of production operations by using reliable advanced systems.

Inventory management plays a big role today in most manufacturing organizations. You have to constantly educate your planning and inventory control personnel to make them an expert in optimizing your inventory level to suit your schedules and capacity for the profits of your organization.

After attending this program, participants should be able to:

• Achieve faster responses & on time delivery to customers
• Obtain better understanding of the planning/scheduling processes and best practices
• Learn how lean manufacturing & a flexible system can impact on planning and scheduling
• Utilize major applications of production planning & control methods used today
• Identify manufacturing operation process, layout, systems design & redesign
• Forecast the management demand
• Acquire final assembly scheduling & sequencing techniques
• Implement material planning process
• Integrate the Master Production Schedule with manufacturing operations
• Discover new facility, capacity planning & control techniques

ELEMENTS OF PRODUCTION PLANNING OPERATIONS, SCHEDULING & CONTROLS

• Purpose & advantages of production planning, order sequencing, production scheduling, control, manufacturing operation process
• Sources of production control
• Characteristics of modern manufacturing management
• MRP II process & Lean manufacturing
• Symptoms & problems of poorly designed systems
• Schedule instability: causes & remedies
• Production planning procedure of a job order concern
• Information integration & workflow
• Types of information flow in PPC
• Control of Resources - material, labor, expenses, process control

MASTER PRODUCTION SCHEDULING (MPS)

• Forecasting & sales order management
• Master production scheduling (MPS) activity
• Business planning
• Aggregate planning
• Team Activities: Owning your dream car
• Components of the MPS
• Link between MPS & MRP
• Purchasing supplier link in MPS/MRP
• Planning bill of materials
• Final assembly scheduling

PRODUCTION & OPERATION PLANNING

• Sales order & work order balancing
• Bills of Materials
• Engineering Change Management
• Line Efficiency & improvement

PRODUCTION SCHEDULING & TECHNIQUE

• Scheduling objectives
• Job scheduling
• Forward/Back scheduling
• Input/Output control
• Dispatching rules - FIFS, SPT etc

JOB PLANNING & SCHEDULING

• Job flow procedure
• Rough cut capacity planning
• Annual production plan
• Sequencing
• Scheduling Techniques
  • short term scheduling
  • short interval scheduling
• Participants to discuss on Scheduling Problems and Group Presentations
• Determination of capacity

CAPACITY REQUIREMENTS PLANNING

• Types of capacity planning
• Factors affecting facility & capacity planning
• Optimizing the use of capacity
• Capacity planning & control techniques
• Finite & infinite capacity techniques
• Define work centres or stations & cost centres
• Case Study on decision tree analysis
• Managing schedule changes & loading
• Procedures for control schedule changes - policies & rules
• Formulate performance indices to measure changes
• Establishing feedback & communication system
• Understanding of JIT Manufacturing

MATERIALS PLANNING & INVENTORY MANAGEMENT

• Materials Requirement Planning (MRP II)
• Independent and dependent demands
• Materials planning process
• Inventory planning involving management and control
• Finished good inventories control

LEAN MANUFACTURING

• Overview of Lean and it's history
• Understand values and wastes in our organization
• Kanban Pull system and how to use it for scheduling
• e-Commerce solutions to improve your workflow
• Lean success stories

UTILIZING THEORY OF CONSTRAINT (TOC) FOR PLANNING

• What is TOC?
• Bottleneck and non bottleneck resources
• Generic TOC principles
• Drum-buffer-rope (DBR) scheduling

INITIATING THE PLANNING & CONTROL ACTIVITIES

• Forecasting for production/manufacturing:
  • demand & demand management
  • the nature & importance of forecasting
  • determining forecast accuracy
• Forecasting techniques
  • statistical analysis
  • moving averages
  • exponential smoothing
  • trends and seasonality
  • the accuracy & monitoring of forecasts

MANUFACTURING SYSTEMS DESIGN

• Relationship between production planning & control and manufacturing systems
• Integrating new technologies

JUST-IN-TIME MANUFACTURING STRATEGY

• JIT production: set up time reduction, Kanban operation, small lot production
• Total quality control: quality at the source & zero defect
• JIT vs MRP II
• Push & pull manufacturing strategies
• Implementation of JIT with manufacturing resource planning

FUTURE DIRECTION

• Impacts of flexible manufacturing system (FMS) & Computer Integrated Manufacturing (CIM) on production planning & control
• Flexible manufacturing systems
• Robotics
• Future directions in production planning & control

GROUP DISCUSSIONS & CASE STUDY

Participants will break into groups to discuss problems and issues relating to production planning & control. Performance Indicators for PPC. Presentations by participants

• Practical Production Planning & Control
• Understanding Incoterms 2010
• Theory of Constraints in Manufacturing
• New Shop Floor Management
• Inventory Management in the Supply & Demand Chains
• More other Manufacturing Operations related courses