EFFECTIVE PRODUCTION PLANNING AND CONTROL

SYNOPSIS: For efficient, effective and economical operation in a manufacturing unit of an organization, it is essential to integrate the production planning and control system. Production planning and subsequent production control follow adaption of product design and finalization of a production process.

Production planning and control address a fundamental problem of low productivity, inventory management and resource utilization. Production planning is required for scheduling, dispatch, inspection, quality management, inventory management, supply management and equipment management. Production control ensures that production team can achieve required production target, optimum utilization of resources, quality management and cost savings.

COURSE OBJECTIVES

Upon completion of this training, you should be able to;

• Compare and contrast various material requirements planning (MRP) systems.
• Describe a master production schedule and the information it provides.
• Apply MRP principles to the provision of services and distribution inventories.
• Reduce lead times;
• Improve on time delivery;
• Reduce costs;
• reduce working capital requirements;
• improve profitability and return on capital

COURSE CONTENT

Introduction to production planning and control

• Purpose of production planning, order sequencing, production scheduling and production control
• Manufacturing operation process – production philosophy
• Advantages of production control
• Sources of production control
• Characteristics of modern manufacturing management – MRP II process

Frame work of production planning and control

• Problems faced by production managers in diverse manufacturing units
• Resolving the issues
• Strategies for production planning and control

Master Production Scheduling (MPS)

• Forecasting and demand management
• Master production scheduling (MPS) activity
• Symptoms of MPS
• Aggregate planning
• Work exercises

Capacity Requirement Planning

• Capacity management and planning
• Types of capacity planning
• Factors affecting facility and capacity planning

Materials Requirement Planning (MRP II)

• MRPII overview
• Independent and dependent demands
• Materials planning process

Inventory Control (IC)

• Inventory planning involving management and control
• Finished goods inventories control
• Calculations on lot order sizing

Production Scheduling and Technique

• Scheduling objectives
• Job scheduling –Forward/Back scheduling
• Input/output control
• Dispatching rules –FIFS, ODD, SPT. Etc
• Critical ratio rule

Theory of constraint (TOC) principles

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

Just-In-Time Manufacturing

• Principles of JIT
• Identify the causes of JIT wastes
• JIT manufacturing key activities and its features
• JIT implementation and its draw back.
• Continuous improvement
• The primary causes of inventories
• Schedule released and planned areas

TARGET AUDIENCE: Plant Managers, Senior Production, Maintenance and Operations Managers, Line Production Supervisors and Production Engineers, inventory planners, master planners, master schedulers, production and maintenance first line supervisors. In addition accounting and financial personnel, Purchasing Agents and those involved with implementing Just-In-Time and Manufacturing Resource Planning initiatives will benefit greatly.