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Production planning and control
The document outlines the production planning and control process for a group project consisting of 4 members. It defines production planning, discusses horizon levels and objectives. It also covers forecasting, product design, routing, materials requirements planning, scheduling, loading, production control forms and functions, control systems, and provides a specific production plan for Kakar Steel Mills.
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Production planning and control
- 1. GROUP MEMBERS FAHEEM ULLAH12-PWMEC-3333 HASAN ALI 12-PWMEC-3393 IRFAN ULLAH 12-PWMEC-33 M.ARSALAN 12-PWMEC-3401 PRODUCTION PLANNING
- 2. Production Plan Definition Horizonlevels Objectives Requirements Functions Forecast Planning Product Design Routing (Process Planning) Material Requirements Planning Scheduling Loading Production Control Definition Forms Functions Dispatching Inspection Evaluation Control Systems Specific Production Plan Production Planning And Control
- 3. Production Plan • Productionplanning involves management decisions on the resources that the firm will require for its manufacturing operations and the selection of these resources to produce the desired goods at the appropriate time and at the least possible cost • Production planning is dynamic in nature and always remains in fluid state as plans may need to be change. Short Term (operational) Medium Term (Aggregate Planning) Long Term (Capacity Planning) Manufacturing system Objectives Constraints -Budget, Space Resources Men Equipment Demand Forecast Planning Process Horizon Levels
- 4. Objectives Minimize Maximiz e inventoryCost Efficienc y of Plant Profits Custom er Service Requirements Should Bebased On Accurate Data simple and straight forward Flexibility Reporting system
- 5. Functions Estimating andForecast Planning Process of predicting a future event based on historical data Forecast Horizon Levels/ timeTechniques Qualitative Methods Quantitative Methods Market Survey Executive Judgmen t Short <3 M Job/Workers Assignment Medium Range 3-24 M Sales/PP Long Range >24 M New PP M=Month Quantitativ e methods Qualitative Methods Quality Forecast Demand Pattern forecast
- 6. Forecasting During LifeCycle Market Survey Moving Averages Executive Judgment Exponential Introduction Growth Maturity Decline Time Qualitative Models Quantitative Models
- 7.
- 8. ProcessPlanning • Process planningdetermines how a product is to be manufactured. • Process planning is an interface between design and manufacturing. Product Design Manufacturing Process ProcessPlanning
- 9. • Production Types• Product Life Cycle TimeDemand Introduction Growth Maturity Decline Variety Volume Project Job Batch Mass Continuo us HighLow HighLow
- 10. Material Requirements Planning Materialsrequirements planning (MRP) is a computerized inventory planning and control system for determining when (no earlier and no later) and how many of each of the parts, components, and materials should be ordered or produced. The basic idea is to get the right materials to the right place at the right time. Inputs
- 11. Material Requirements Planning MasterProduction Schedule Materials Requirement Planning Bill Of Materials Reports Inventory Status Purchasing Data
- 12. Loading & Scheduling: Loading is the assignment of Work to the workers and equipment. Scheduling involves fixing the priorities for different jobs and deciding the starting and finishing time (or date) of each job. Also called as time based loading. Loading & Scheduling Charts Master Production Schedule Operation Schedule Gantt Chart
- 13. Production Control Productioncontrol guides and directs flow of production to ensure that all which occurs is in accordance with the rules established and instructions issued. Production Control Forms of PC Functions of PC Quality control Dispatching Evaluation Inspection Cost control Stock control
- 14. ControlSystems • Open Loopcontrol System • Closed Loop control System Transformatio n Output Simple but no Feed back Channel Transformatio n Output Resources & Objective Products & Service Comparison Measures Corrective action Have Feed Back & Control
- 15. Specific Production Plan KakarSteel Mills Production Plan Product Forecas t
- 16. Specific ProductionPlan (Continued) Process Planning (Routing) Flat & Shape Rolling Process
- 17. Specific ProductionPlan (Continued) Materials Requirement Planning
- 18. Specific ProductionPlan (Continued) Scheduling And Loading Shortest possible Time Scheduling
- 19. Specific ProductionPlan (Continued) controlling Inspection Quality Control Lab XRF OESNDT Tensile, Compression And Bending Tests Metallography BHN Test