The document summarizes Card Based Production Planning & Control (PPC) System. It describes the system's components including a loop of cards between the shop floor and planning office and card display boards. It explains how the system works through phases like order entry, process planning, job release and execution. The system aims to provide realistic delivery times for customers by monitoring current workload and throughput. It also demonstrates the system with a sample of jobs and order entry. The document outlines the system's fundamentals including work breakdown structure, routing operations, shop design and training. It describes what the card system does and does not do in production planning and control.

1. Card Based Production
Planning &Control (PPC)
System
Presented by [Ibrahim Mohammed]

2. Problem Statement
Q: How can we quote realistic delivery times
for Customer Order?
Ans:
• A system to keep stock and estimate
current workload and shop through-put
• A system to sequence product
transformation
• A system to monitor and control product
transformation

3. PPC Options
Kanban
5s
Lean
MRP
TPS
JIT
Six Sigma
OPT
POLCA

4. How To Choose?

5. Workload Control (WLC) Concept
• “Based on creating predictable and short
through-put times for each critical work
station”
• “predictable throughput times are important
for a good timing of order releases, for
quoting realistic delivery times, and for good
timing of capacity adjustments.”

6. SYSTEM COMPONENTS
1. Loop of Cards between the Shop Floor and
the Planning Office
2. Card Display Boards
3. Order Guiding Form
4. Support Staff

7. How it Works (Phases)
• Order Entry Phase
• Process Planning Phase
• Job Release Phase
• Job Execution Phase (Shop Floor)
• Monitoring and Control

8. How it Works (Process Flow)
.

9. Demo (Today: Jan-01)
Jobs Simulation:
• Mickey Sculpture
• Oryx Sculpture
• Tweety Bird Cage
• AWR Farmhouse Pot Type 4
• KZ Doha Airplane Turbine
• Uniflora Pot Type 1
• VM Accessories Risers
• LMG Feature Wall Cutouts
• Frit Panels

10. Demo (Order Entry: Easter Eggs)
.

11. Fundamentals (Axioms)
Pillar 1: WBS
• Customer orders (products) can be broken down into sub-components
that can be routed independently, and produced as a set of basic
operations
Pillar 2: Routing/Operations Sequence
• Each subcomponent can be designed as a sequence of simple,
repetitive operations
Pillar 3: Shop Design/Structure
• The shop floor is designed to integrate human labor and machine
• Shop is divided into work centers i.e. where and when an operation
must be performed
• Shop operations are categorized by work centers
• Job dispatching rules/Job processing rules are established
Pillar 4: Training
• Training in skills and teamwork

12. Pillar 1: WBS
.

13. Pillar 2: Routing/Operations
Sequence
Cutting Room → Carving → Modeling (Application of Clay) →
Modeling (Detailing of Clay) → Metal Fabrication (Steel Framework)
→ Mold Making → GRP (Casting) → GRP (Tooling/Stamping) →
Metal Fabrication (Base Plate) → Surface preparation → Renderring
JOB ROUTING
Each Job Route = 1 Job Card → 1 Job Stage
Each Job Card = Complete List of Operation at a Job Stage

14. Pillar 2: Routing/Operations
Sequence ID WORK CENTRE
1 Cutting Room
2 Carving
3 Modeling
4 Modeling
8 GRP (Tooling)
9 Metal Fabrication
10 Surface Prep.
11 Artistry
Apply Top Coat paint on sculpture and base plate
12 Paint Finishing
6
7 GRP (casting)
Apply Epoxy Primer to base Plate
Paint base plate
Attach metal baseplate to feet of sculpture, as in drawing
Wash out excess wax, carry out light sanding of smooth areas,
apply primer
make rendering of the sculpture as per reference image
provided and approved pantone colors
Mold Making5
Metal
Fabrication
Fabricate Metal Framing for Sculpture
Fabricate metal baseplate for sculpture
Demarcate the model with forex cards according to the
number of parts of the mold required
Make rubber mold with hard backing of each part of the
After curing is completed, release the mold by removing the
model, then degrease the mold by washing with soap and
pressurised water
Cast the product in 2 layer GRP + Metel Frame (Armature)
After curing is complete, release product from mold
Trim out excess material on the product along the line of
DETAILS OF OPERATIONS
Cut EPS model of product to scale of 1:1
Assemble and carve out shape of product, by hand
Mold clay on the EPS model
Imprint body details of sculpture onto the clay molded on the
EPS model
Apply wax over the entire surface area of the model

15. Pillar 3: Shop Design/Structure
WORK
CENTER
FOREMAN
TEAM
LEADER 1
TEAM
MEMBER 1
TEAM
MEMBER 2
TEAM
MEMBER 3
TEAM
MEMBER 4
TEAM
LEADER 2
TEAM
MEMBER 1
TEAM
MEMBER 2
TEAM
MEMBER 3
TEAM
MEMBER 4
Team Structure (unit of organization)
Operations Categories (basis of categorization)

16. Pillar 4: Training
Supervision
Leadership
Teamwork

17. Resource Requirement
Process Planning Phase
• Process Planner
Job Release Phase
• Release Planner
Shop Floor
• WIP-Inventory Controller
Monitoring and Control Phase
• Planning Data Officer (Data Control and
Analysis)
***most importantly: PLANNING ROOM

18. What the Card System Does
• Reduces uncertainty in the control decision
by using feedback loops that update the
current situation on the shop floor in real
time
• Coordinate the flow of products through the
system
• Coordinate the flow of products in
accordance with the availability of
transforming resources
• Reduce waiting waste i.e. free up capacity

19. What the card System Does Not
Do
• Does not ensure quality- ensuring quality is the job of Total Quality
Mgt. (TQM) or Six Sigma
• Does not improve efficiency of material transformation
process- this is the job of design and engineering
• Does not improve efficiency of an operation itself- this is the job
of motion studies, improved job design, or improved product design
• Does not make unreliable machines reliable- this is the job of
Total Productive Maintenance (TPM)
• Does not reduce transportation waste
• Does not solve the problem of multiple points of control
• Does not solve the problem of “Jaldi Jaldi”
• Does not solve the problem of cashflow/material approval

20. Scaling Up
• Integration of QC Function
• Integration of Sales/Marketing Function
• Integration of Materials Inventory/Store
• Automation