Production Planning, Scheduling and Control

This course will address the principles of production planning and inventory control using the best practices in modern manufacturing theories and practices. Participants will gain greater appreciation to the benefits of positioning their operations and optimise the value from the supply chain.

Participants will gain appreciation and develop their own creative solutions in areas such as implementation of company-wide measurement and control systems, addressing inventory reduction challenge without compromising customer satisfaction.

Material requirements planning (MRP) is a system used to avoid situations where parts are missing. It establishes a schedule (priority plan) showing the components required at each level of the assembly and, based on lead times, calculates the time when these components will be needed.

Objective

• This course is designed to teach skills in the planning & control of production for improved sectional & organizational effectiveness. Experiential learning cycles will be used to ensure maximum benefit to participants.

On completion of this course, participants should be able to:

• Improve production planning techniques
• Improve process schedule
• Improve job planning & control
• Improve productivity & problem solving techniques

Day One
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

Day Two
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

Day Three
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

Day Four
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

Day Five
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