The document outlines production scheduling principles and the importance of effective planning in manufacturing, highlighting the interdependencies of various functional departments. It emphasizes the need for prioritizing urgent orders, understanding production capacity, and employing effective scheduling models to enhance efficiency. Additionally, it discusses the use of Excel tools for scheduling and defines the critical elements of materials requirements planning and master production scheduling.

1. Production Scheduling－－ Dick LamTime present and time pastAre both perhaps present in time futureAnd time future contained in time past

2. There is a long process in Sales & Marketing before we are committed to PRODUCTIONIdentifyProposeContactMeetMake Sale

3. ScheduleMaster Production ScheduleMaterals PlanningProduction心寛室自大, 室小心乃寛

4. Production – the core of a factory operation1. ProductionAdd value to customers, needs support from every functional depts of the factory2. All Other Functional DeptsIncluding Purchasing, Material, Engineering, Quality, HR & Admin, Finance & etc

5. TimeWorkforceInventoryProduction capacity cannot be storedOperators are not flexible actuallyIncorrect planning leads to increase in Inventory!Why matters?

6. First thing firstDo the urgent thing first!

7. Put down everything and just focus on ABC order

8. Production Manager and supervisors should walk through the lines and ensure all people are doing ABC order.

9. WE are team. We can make it!!Expedite the order of ABC company, now!!

10. ABC order – the most urgent order!!1. ABC orderAll Other orders

11. Caution!! XYZ is Urgent!!ShippedABC Order shippedBut All other orders are messy!!!

12. More Equipment/FacilityWe need more capacity!!!More Space/People

13. But there is nothing to do in production lines SOMETIMES!!!

14. Agenda654321Scheduling – Model II (Sequential Processing, Pull & Push)Scheduling – Model I (Multiple Machines for Single Job Task)Scheduling – Simplified Version (Single Production Line)Scheduling PrinciplesExcel BasicsExcel – User Defined Functions LibraryChallenge up, Support Down

15. Contact DetailsMr. Dick Lam Chor Kidicklam128@hotmail.comhttp://dicklam128 .wordpress.com

16. DisclaimerNo Best Practice provided in this course

17. Only Low Hanging Fruit

18. The Best Solution is unquestionably the ERP under the condition that you strictly follow the ERP environment specified

19. HOWEVER, we provide you Bridges of:

20. Knowledge

21. Thinking

22. OperationScarcityWe only manage the time in terms of hours

23. Before doing anything

24. 1. Excel BasicsFunctions reviewMin, MaxVlookupSumif, SumifsSumproductIferrorRange NameDefine, CreateDynamic Range

25. 2. Excel User Defined FunctionsYou can write some functions like “sum”, “sumif” with the parameters you definee.g. =sumxy(Cell1, Cell2)e.g. =factorial(Cell1)The file stored should be with .xlsmYou can also package all the user defined functions into a library.The file stored should be with .xlam

26. Developer Environment

27. Library: DLSupplyChain.xlamThe Excel library developed by Dick Lam for Supply Chain managementIt contains various functions for production scheduling modelBe 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

28. Put it in the following folder: C:\Program Files\Microsoft Office\Office12\XLSTARTThe library will open automatically whenever you start up ExcelHowever, for users without this library in the above folder(particularly you distribute the file to others), they cannot see the result but “error”

29. Add-inPut it in any folder while the following is preferred:C:\Documents and Settings\user\Application Data\Microsoft\AddInsThen go to register it in the Add-in manager

32. 3. Scheduling PrinciplesPull or Push principlesFirst Deliver First ScheduledIdentify Weakest Link/Critical Path and then exploitIdentify the non-critical Path as well as the spare capacitySchedule the identical/similar components in continuous order不知其源, 焉知其流?

33. Master Production ScheduleFor formula construction, please refer to the:Master Production Schedule.xlsx

34. Excel ModelWorkshop

35. Basic FormulaOpening + In – Out = ClosingOpening + Production – Sold = ClosingProduction = Closing – Opening + SoldClosing = Summation of Units to be sold of future days covered by Target Inventory Days

37. Using today capacity for tomorrow demandFuture spare capacity cannot be used to cover today/yesterday unfulfilled demand

38. MPS – Full ModelThe user defined function is included in the library of “DLSupplyChain.xlam”

39. 4. Single Production LineIt is scheduling of various job orders in a single production lineFocus on the achievability of job ordersResults:When to start and when to completeHow many hours to complete including set up & set down timeHow many hours of spare capacity and how many quantity not achievedWhen to change die

40. A Snapshot

41. It is the core of all kinds of schedulingMultiple machines for single job taskSequential processing

42. Excel ModelWorkshop

43. 5. Multiple Machines for Single Job TaskFor 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.

44. Parallel Processing

45. Model HighlightBased 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.A line schedule is produced telling the following:What orders to produce over a certain period of time (week by week)When to switch productHow many operators required

46. A SnapshotThere is spare capacity for Job No.12 in R102 but the end date will be after ready date, therefore, it is allocated to R103Job No.9’s ready date is Feb 4, but the capacity of days on and before Feb 4 have been used up, so it is allocated to R102; however, Job No.10 being with Feb 5 can stay on R102

47. Excel ModelWorkshop

48. 6. Sequential ProcessingFor 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