Production scheduling(draft agenda)


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This is the draft agenda of the training seminar of Production Scheduling. You are welcome to provide your suggestion on the content of this seminar.

You can write me to the following email address:

The training seminar of Production Scheduling is expected to launch on April 2011 both in Hong Kong and Shanghai.

If you are interested in joining the training seminar, you can contact the following training institution:

Hong Kong:


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Production scheduling(draft agenda)

  1. 1. Production Scheduling<br />-- Dick Lam<br />Time present and time past<br />Are both perhaps present in time future<br />And time future contained in time past<br />
  2. 2. There is a long process in Sales & Marketing before we are committed to PRODUCTION<br />Identify<br />Propose<br />Contact<br />Meet<br />Make Sale<br />
  3. 3. Schedule<br />Master Production Schedule<br />Materals Planning<br />Production<br />心寛室自大, 室小心乃寛<br />
  4. 4. Production – the core of a factory operation<br />1. Production<br />Add value to customers, needs support from every functional depts of the factory<br />2. All Other Functional Depts<br />Including Purchasing, Material, Engineering, Quality, HR & Admin, Finance & etc<br />
  5. 5. Time<br />Workforce<br />Inventory<br />Production capacity cannot be stored<br />Operators are not flexible actually<br />Incorrect planning leads to increase in Inventory!<br />Why matters?<br />
  6. 6. First thing first<br /><ul><li>Do the urgent thing first!
  7. 7. Put down everything and just focus on ABC order
  8. 8. Production Manager and supervisors should walk through the lines and ensure all people are doing ABC order.
  9. 9. WE are team. We can make it!!</li></ul>Expedite the order of ABC company, now!!<br />
  10. 10. ABC order – the most urgent order!!<br />1. ABC order<br />All Other orders<br />
  11. 11. Caution!! XYZ is Urgent!!<br />Shipped<br />ABC Order shipped<br />But All other orders are messy!!!<br />
  12. 12. More Equipment/Facility<br />We need more capacity!!!<br />More Space/People<br />
  13. 13. But there is nothing to do in production lines SOMETIMES!!!<br />
  14. 14. Agenda<br />6<br />5<br />4<br />3<br />2<br />1<br />Scheduling – Model II (Sequential Processing)<br />Scheduling – Model I (Multiple Machines for Single Job Task)<br />Scheduling – Simplified Version (Single Production Line)<br />Scheduling Principles<br />Excel Basics<br />Excel – User Defined Functions Library<br />Challenge up, Support Down<br />
  15. 15. Contact DetailsMr. Dick Lam Chor Ki<br /><br />http://dicklam128<br />
  16. 16. Before doing anything<br />
  17. 17. 1. Excel Basics<br />Functions review<br />Min, Max<br />Vlookup<br />Sumif, Sumifs<br />Sumproduct<br />Iferror<br />Range Name<br />Define, Create<br />Dynamic Range<br />
  18. 18. 2. Excel User Defined Functions<br />You can write some functions like “sum”, “sumif” with the parameters you define<br />e.g. =sumxy(Cell1, Cell2)<br />e.g. =factorial(Cell1)<br />The file stored should be with .xlsm<br />You can also package all the user defined functions into a library.<br />The file stored should be with .xlam<br />
  19. 19. Developer Environment<br />
  20. 20. Library: DLSupplyChain.xlam<br />The Excel library developed by Dick Lam for Supply Chain management<br />It contains various functions for production scheduling model<br />Be reminded to put in the same folder of your supply chain model, but you need to manually open it whenever you open any Excel files which use the functions contained<br />
  21. 21. Put it in the following folder:<br /> C:Program FilesMicrosoft OfficeOffice12XLSTART<br />The library will open automatically whenever you start up Excel<br />However, for users without this library in the above folder(particularly you distribute the file to others), they cannot see the result but “error”<br />
  22. 22. 3. Scheduling Principles<br />Pull System<br />First Deliver First Scheduled<br />Identify Weakest Link/Critical Path and then exploit<br />Identify the non-critical Path as well as the spare capacity<br />Schedule the identical/similar components in continuous order<br />
  23. 23. Master Production Schedule<br />For formula construction, please refer to the:<br />Master Production Schedule.xlsx<br />
  24. 24. Basic Formula<br />Opening + In – Out = Closing<br />Opening + Production – Sold = Closing<br />Production = Closing – Opening + Sold<br />Closing = Summation of Units to be sold of future days covered by Target Inventory Days<br />
  25. 25.
  26. 26. Using today capacity for tomorrow demand<br />Future spare capacity cannot be used to cover today/yesterday unfulfilled demand<br />
  27. 27. MPS – Full Model<br />The user defined function is included in the library of “DLSupplyChain.xlam”<br />
  28. 28. 4. Single Production Line<br />It is scheduling of various job orders in a single production line<br />Focus on the achievability of job orders<br />Results:<br />When to start and when to complete<br />How many hours to complete including set up & set down time<br />How many hours of spare capacity and how many quantity not achieved<br />When to change die<br />
  29. 29. A Snapshot<br />
  30. 30. It is the core of all kinds of scheduling<br />Multiple machines for single job task<br />Sequential processing<br />
  31. 31. 5. Multiple Machines for Single Job Task<br />For multiple job orders, says 100 within a week, which use the same kind of machinery or production lines, it is to allocate job order to related machines/production line with consideration of certain conditions (constraints) and tell the user if it can be achieved.<br />
  32. 32. Parallel Processing<br />
  33. 33. Model Highlight<br />Based on the priority of the machines & expected completion date, it will assign quantities to various equivalent machines so as to meet the expected completion date.<br />A line schedule is produced telling the following:<br />What orders to produce over a certain period of time (week by week)<br />When to switch product<br />How many operators required<br />
  34. 34. A Snapshot<br />
  35. 35. 6. Sequential Processing<br />For job orders which requires >1 sequential processes, or even with more together with parallel processes of pre-conditions, it is to allocate the job orders to related process and evaluate whether it can be completed on time<br />
  36. 36. Sequential Processing<br />
  37. 37. A Snapshot<br />
  38. 38. Conclusions<br />3 Steps for Production Planning<br />Master Production Schedule<br />Materials Planning<br />Production Scheduling<br />
  39. 39. Define your conditions<br />Time gap between Delivery Date & Production Completion Date (Target Inventory Weeks)<br />Identify the capacity flexibility<br />Identify the weakest link<br />