Programa ECO Execution and Control of Operations – APICS CPIM Objetivos: A aChain é empresa APICS Channel Partner e realizará o curso de revisão do módulo ECO Execution and Control of Operations. O módulo ECO trata de quatro áreas: execução dos planos operacionais e controle da operação; controle e análise de resultados dos produtos manufaturados e serviços executados; gestão da comunicação no ambiente de trabalho; e, a importância de utilizar os princípios de projeto da operação corretamente. O módulo explica as técnicas de scheduling e controle da operação em relação à capacidade disponível, gestão da qualidade, sistemas de custeio e metodologias de resolução de problemas, apresentando as melhores técnicas e iniciativas para gestão de recursos, gestão ambiental e atividades de melhoria contínua. O módulo ECO é o módulo da execução. Participantes que atuam diretamente na operação da fábrica sentirão em casa quando tratarmos de assuntos como liberação de ordens de produção, ordens de compra, gerenciamento controle da produção, células de manufatura, linhas de produção, controle de lotes, filosofia lean, nivelamento da produção, gerenciamento da qualidade, seis sigmas e controle de estoques. Falando especificamente de lean, trataremos dos principais conceitos, incluindo takt time, cycle time, pacemaker, store, throughput, andon (行灯), gemba (現場), genchi genbutsu (現地現物), hansei (反省), heijunka (平準化), jidoka (自働化), JIT – Just-In-Time (ジャストインタイム), kaizen (改善), kanban (看板), muda (無駄), mura (斑), muri (無理), nemawashi (根回し), poka-yoke (ポカヨケ) e hoshin planning. Temos alguns filmes que ajudarão no entendimento e aplicação dos conceitos. O módulo ECO ainda trata de comunicação no ambiente de trabalho, gerenciamento de equipes, projeto da rede de abastecimento e DOE – Design of Experiments. No final do ECO tem uma seção com alguns cases para aplicar os conhecimentos. Tópicos: Session 1-Execution of Operations Session 2-Scheduling and Authorization Session 3-Control Of Production Session 4-Control of Costs and Quality Session 5-Management and Communication Session 6-Quality and Continuous Improvement Session 7-Design Tradeoffs Session 8-Case Studies

1. Table of Contents
ECO CPIM
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Programas CPIM e CSCP abertos e in company

3. Table of Contents
Participant Workbook Page
Table of Contents
Session 1—Execution of Operations
Manufacturing Planning ................................................................................................. 1-9
Manufacturing Planning Hierarchy ........................................................................................................... 1-9
Strategic and Business Planning: Direction- Setting ................................................................ 1-11
Manufacturing Planning and Control: Tactical Operations ...................................................... 1-13
DSP and ECO (Near Term Operations) ...................................................................................... 1-15
Defining Execution and Control Systems ...................................................................... 1-19
Manufacturing Environments .................................................................................................... 1-19
Process Choices ......................................................................................................................... 1-21
Process Layouts .......................................................................................................................... 1-23
Batch Versus Flow Process Implications .................................................................................. 1-25
Push Versus Pull Principles ....................................................................................................... 1-27
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4. Execution and Control Of Operations
Session 2—Scheduling and Authorization
MRP-Based Scheduling .................................................................................................. 2-7
MRP-Based Schedule Elements and Inputs .............................................................................. 2-9
Interface With Material and Capacity Requirements Planning ................................................ 2-11
Operations Scheduling Techniques ........................................................................................... 2-13
Other Scheduling Issues ............................................................................................................. 2-31
Theory of Constraints Scheduling .................................................................................. 2-37
Lean Scheduling ...................................................................................................................... 2-41
Overview ...................................................................................................................................... 2-41
Key Elements and Goals of Lean Systems ................................................................................ 2-43
Interface With Manufacturing Planning ..................................................................................... 2-45
Production Leveling .................................................................................................................... 2-47
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5. Table of Contents
Participant Workbook Page
Session 3—Control Of Production
Scope and Principles of Operations Control ................................................................. 3-7
Production Activity Control ......................................................................................................... 3-9
Quality Control ............................................................................................................................ 3-11
Production Activity Control: MRP-Based ....................................................................... 3-13
Scheduling and Control Interfaces ............................................................................................ 3-13
PAC in Batch Production and Flow Manufacturing ................................................................... 3-15
Control Techniques .................................................................................................................... 3-19
Production Activity Control: Lean Based ....................................................................... 3-35
MRP- Versus Lean-Based Control Systems .............................................................................. 3-35
Production Control in Lean Systems ......................................................................................... 3-37
Heijunka ...................................................................................................................................... 3-39
Takt Time .................................................................................................................................... 3-41
Pacemaker .................................................................................................................................. 3-43
The Store ..................................................................................................................................... 3-45
Kanban System .......................................................................................................................... 3-47
Transaction Simplification ......................................................................................................... 3-55
Inventory Management Issues ....................................................................................... 3-57
Customer Service, Inventory Investment, and Efficiency ......................................................... 3-57
Inventory Storage ....................................................................................................................... 3-59
Inventory Identification .............................................................................................................. 3-63
Inventory Accuracy and Counting .............................................................................................. 3-67
Accounting Classification ........................................................................................................... 3-71
Vendor Managed Inventory ........................................................................................................ 3-73
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© 2014 APICS iii Instructor Guide Version 3.3

6. Execution and Control Of Operations
Session 4—Control of Costs and Quality
Cost Control .................................................................................................................... 4-7
Cost Control Overview ................................................................................................................. 4-9
Product and Period Costs ........................................................................................................... 4-11
Job Order and Process Costing .................................................................................................. 4-13
Absorption and Variable Costing Methods ................................................................................ 4-21
Activity Based Cost Accounting .................................................................................................. 4-23
Cost Variances ............................................................................................................................ 4-25
Cost of Quality ............................................................................................................................. 4-31
Control of Quality ............................................................................................................ 4-35
Quality Planning .......................................................................................................................... 4-37
Types of Quality Problems .......................................................................................................... 4-39
Statistical Quality Control ........................................................................................................... 4-43
Process Capabilty ........................................................................................................................ 4-59
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7. Table of Contents
Participant Workbook Page
Session 5—Management and Communication
Approaches to Management ..........................................................................................5-7
Taylor’s Scientific Management ................................................................................................ 5-7
Worker Self-Control .................................................................................................................... 5-9
Management Leadership ........................................................................................................... 5-11
Worker Development ......................................................................................................5-19
State of Self-Control and Responsibility ................................................................................... 5-19
Principles for Worker Development........................................................................................... 5-21
Worker Participation and Involvement ..........................................................................5-35
Types of participation and Involvement .................................................................................... 5-37
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© 2014 APICS v Instructor Guide Version 3.3

8. Execution and Control Of Operations
Session 6—Quality and Continuous Improvement
The Seven Basic Quality Tools ....................................................................................... 6-7
Six Sigma DMAIC ............................................................................................................ 6-21
Define ..........................................................................................................................................6-21
Measure.......................................................................................................................................6-23
Analyze .........................................................................................................................................6-25
Improve ........................................................................................................................................6-25
Control .........................................................................................................................................6-27
PDCA Cycle ...................................................................................................................... 6-29
PDCA Activities ............................................................................................................................6-31
Plan ..............................................................................................................................................6-33
Do .................................................................................................................................................6-35
Check ...........................................................................................................................................6-35
Act ................................................................................................................................................6-35
A3 Problem Solving ........................................................................................................ 6-37
Problem-Solving A3 Report .........................................................................................................6-39
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 3.3 vi © 2014 APICS

9. Table of Contents
Participant Workbook Page
Session 7—Design Tradeoffs
Design Principles ............................................................................................................7-7
Local Design Principles .............................................................................................................. 7-9
Network Design Principles ......................................................................................................... 7-15
Global Design Principles ............................................................................................................ 7-21
Design Techniques ..........................................................................................................7-25
Supply Network Performance .................................................................................................... 7-25
Improving Supplier Performance and Relationships ............................................................... 7-27
Customer Performance and Relationship Improvements ....................................................... 7-49
Design of Experiments ............................................................................................................... 7-57
Visual Management ................................................................................................................... 7-61
Workplace Design ....................................................................................................................... 7-65
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
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10. Execution and Control Of Operations
Session 8—Case Studies
Case Studies ................................................................................................................... 8-7
Case Study: Productiojn Process Analysis—Overview ...............................................................8-7
Case Study Part 1: Functional Layout Analysis .........................................................................8-9
Case Study Part 2: Cellular Layout Design ................................................................................8-25
Appendix
Progress Check Answer Sheet .......................................................................................A-1
Bibliography ....................................................................................................................A-2
Index
Index ................................................................................................................................ Index 1
aChain - APICS International Channel Partner - www.achain.com.br
Programas CPIM e CSCP abertos e in company
Instructor Guide Version 3.3 viii © 2014 APICS