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Production planning and control
1.
2. The need for Production Planning
Demand Forecasting
Aggregate Production Planning
Strategies of Aggregate Planning
Scheduling
Workforce Planning
Materials Requirement Planning
Capacity Planning
Production Control using JIT
Shop-Floor Control
2May-16
3. Addresses decisions on
Acquisition
Utilization
Allocation of limited production resources
Resources include the production facilities, labor
and materials.
Constraints include the availability of resources,
delivery times for the products and management
policies.
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4. Main objective is to take appropriate decisions.
Typical decisions
Work force level
Production lot sizes
Assignment of overtime
Sequencing of production runs
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6. Objective
To predict demand for planning purposes
Laws of Forecasting
Forecasts are always wrong
Forecasts always change
The further into the future, the less reliable the
forecast will be
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7. 7May-16
Description Qualitative Approach Quantitative Approach
Applicability Used when situation is
vague & little data exist
(e.g., new products and
technologies)
Used when situation is
stable & historical data
exist
(e.g. existing products,
current technology)
Considerations Involves intuition and
experience
Involves mathematical
techniques
Techniques Jury of executive
opinion
Sales force composite
Delphi method
Consumer market
survey
Time series models
Causal models
8. Qualitative Demand Forecasting
- if you do not have historical data on your products'
sales
8May-16
Qualitative Method Description
Jury of executive
opinion
The opinions of a small group of high-level managers are pooled and together
they estimate demand. The group uses their managerial experience, and in
some cases, combines the results of statistical models
Sales force composite Each salesperson (for example for a territorial coverage) is asked to project
their sales. Since the salesperson is the one closest to the marketplace, he
has the capacity to know what the customer wants. These projections are
then combined at the municipal, provincial and regional levels.
Delphi method A panel of experts is identified where an expert could be a decision maker, an
ordinary employee, or an industry expert. Each of them will be asked
individually for their estimate of the demand. An iterative process is
conducted until the experts have reached a consensus.
Consumer market
survey
The customers are asked about their purchasing plans and their projected
buying behavior. A large number of respondents is needed here to be able to
generalize certain results.
9. Quantitative Demand Forecasting
There are two forecasting models here – (1) the time series model
and (2) the causal model.
• A time series is a set of evenly spaced numerical data and is
obtained by observing responses at regular time periods. In the
time series model, the forecast is based only on past values and
assumes that factors that influence the past, the present and
the future sales of your products will continue.
• The causal model uses a mathematical technique known as the
regression analysis that relates a dependent variable (for
example, demand) to an independent variable (for example,
price, advertisement, etc.) in the form of a linear equation.
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10. • operational activity that does an aggregate plan
for the production process, to give an idea to
management as to what quantity of materials and
other resources are to be procured and when, so
that the total cost of operations of the
organization is kept to the minimum over that
period
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11. Objective
To generate a medium-term production plan
To establish rough product mix
To anticipates bottlenecks
To align capacity and workforce plans.
Demand changes over a period of time at a faster
rate than the resources. Aggregate planning offers
strategies to absorb these fluctuations.
11May-16
12. Guidelines for Aggregate Planning
Determine demand for each period
Consider company policies that may have impact
Determine capacities for each period
Regular time, overtime, subcontracting, etc.
Identify backorder or inventory amount
Determine costs of operation
Continue through time horizon to calculate total cost
Develop alternate plans and compute cost for each
Select the plan that meets objectives
12May-16
13. 13
Output of Aggregate Planning
Production quantity from regular time, overtime
and subcontracted time
Inventory held for determination of how much
warehouse space and working capital is needed
Backlog or stock-out quantity for determining the
customer service levels
May-16
14. Level plans
Use a constant workforce & produce similar
quantities each time period
Use inventories and backorders to absorb
demand peaks & valleys
Chase plans
Minimize finished good inventories by trying to keep
pace with demand fluctuations
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17. Hybrid or Mixed Strategies
Build-up inventory ahead of rising demand and
use backorders to level extreme peaks
Layoff or furlough workers during lulls
Subcontract production or hire temporary
workers to cover short-term peaks
Reassign workers to preventive maintenance
during lulls
Influencing Demand
17May-16
18. • process of arranging, controlling and optimizing
work and workloads in a production process or
manufacturing process
• used to allocate plant and machinery resources,
plan human resources, plan production processes
and purchase materials
18May-16
19. Concerned with timetable of production
Scheduling arranges the different manufacturing
operations in order of priority, fixing the time & date
for the commencement & completion of each
operation.
19May-16
20. • continual process used to align the needs and priorities of
the organization with those of its workforce to ensure it
can meet its legislative, regulatory, service and production
requirements and organizational objectives
• enables evidence based workforce development
strategies
To find out and direct
Right people
Right place
Right time
Right price
20May-16
22. MRP is a production planning and inventory control
system used to manage manufacturing processes.
An MRP system has 3 major objectives
Ensure materials are available for production and
products are available for delivery to customers
Maintain the lowest possible level of inventory
Plan manufacturing activities, delivery schedules
and purchasing activities
22May-16
23. MRP steps
Takes output from the planning phase (master plan)
Combines that with the information from the
inventory record and product structure records
Determines a schedule of timing and quantities for
each item
The basic idea is to get the right materials to the right
place at the right time.
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26. The process of determining the production
capacity needed to meet changing demands
Maximum amount of work that an organization is
capable of completing in a given period of time
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29. Issues
Stand-alone capacities and congestion effects
Capacity Strategy
Make-or-Buy
Flexibility
Scalability and learning curves
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30. JIT is the technique for reducing inventories and
elimination of waste in the production system.
Objectives
To eliminate waste
To improve quality
To minimize lead time
To reduce costs
To improve productivity
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31. Pull production and kanban
JIT is associated with pull systems.
Toyota was the first developer of kanban system.
Examples
McDonalds'
Office Xerox Paper
31May-16
33. • comprises the methods and systems used to
prioritize, track, and report against production orders
and schedules.
• includes the procedures used to evaluate current
resource status, labor, machine usage, and other
information required to support the overall planning,
scheduling, and costing systems related to shop floor
operation.
• typically calculates work in process based on a
percentage of completion for each order and
operation that is useful in inventory valuations and
materials planning.
33May-16
34. Objective
To control flow of work through plant and coordinate
with other activities (e.g., quality control, preventive
maintenance, etc.)
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36. Functions
Gross Capacity Control
Match line to demand by staffing (workers/shifts)
Varying length of work week (or work day)
Using outside vendors to augment capacity
Contd…
36May-16
37. Functions
Bottleneck Planning
Handling of bottlenecks
Cost of capacity is the key
Stable bottlenecks are easier to manage
Span of Control
Physically or logically decompose system
Span of labor and process management
37May-16
38. Issues
Customization
SFC is often the most highly customized activity in
a plant.
Information Collection
SFC represents the interface with the actual
production processes and is therefore a good
place to collect data. Contd…
38May-16
41. 41May-16
Management Science II, by Dr.T.T. Narendran, IIT
Madras (pdf format)
Shop floor Control, by Wallace J Hopp and Mark
J Spearman, 1996-2000
www.factory-physics.com
Production Planning and Control, Lesson 8, Abha
Kumar
Production and Inventory Control, by Dr. Lotfi K.
Gaafar, 2005 (ppt format)
Manufacturing Planning and Control, by Stephen
C. Graves, MIT Boston, Nov1999 (pdf format)