Production Planning Scheduling and Control

Course details

Overview
Material requirements planning (MRP) is a system used to avoid situations where parts are missing. It establishes a schedule (priority plan) showing the components required at each level of the assembly and based on lead times calculates the time when these components will be needed. This course will address the principles of production planning and inventory control using the best practices in modern manufacturing theories and practices. Participants will gain greater appreciation to the benefits of positioning their operations and optimise the value from the supply chain. Participants will gain appreciation and develop their own creative solutions in areas such as implementation of company-wide measurement and control systems addressing inventory reduction challenge without compromising customer satisfaction.

Objective
This course is designed to teach skills in the planning & control of production for improved sectional & organizational effectiveness. Experiential learning cycles will be used to ensure maximum benefit to participants.
On completion of this courseparticipants should be able to:
Improve production planning techniques
Improve process schedule
Improve job planning & control
Improve productivity & problem solving techniques

Who Should Attend
Plant Managers, Senior Production, Maintenance and Operations Managers, Line Production Supervisors and Production Engineers, inventory planners, master planners, master schedulers, production and maintenance first line supervisors. In addition accounting and financial personnel, Purchasing Agents and those involved with implementing Just-In-Time and Manufacturing Resource Planning initiatives will benefit greatly.

Course Outlines

Day One
Introduction to production planning and control
Purpose of production planning order sequencing production scheduling and production control
Manufacturing operation process - production philosophy
Advantages of production control
Sources of production control
Characteristics of modern manufacturing management - MRP II process
Frame work of production planning and control
Problems faced by production managers in diverse manufacturing units
Resolving the issues
Strategies for production planning and control

Day Two
Master Production Scheduling (MPS)
Forecasting and demand management
Master production scheduling (MPS) activity
Symptoms of MPS
Aggregate planning
Work exercises
Capacity Requirement Planning
Capacity management and planning
Types of capacity planning
Factors affecting facility and capacity planning

Day Three
Materials Requirement Planning (MRP II)
MRPII overview
Independent and dependent demands
Materials planning process
Inventory Control (IC)
Inventory planning involving management and control
Finished goods inventories control
Calculations on lot order sizing

Day Four
Production Scheduling and Technique
Scheduling objectives
Job scheduling Forward/Back scheduling
Input/output control
Dispatching rules FIFS ODD SPT. Etc
Critical ratio rule
Theory of constraint (TOC) principles
What is TOC?
Bottleneck and non-bottleneck resources
Generic TOC principles
Drum-buffer-rope (DBR) scheduling

Day Five

Just-In-Time Manufacturing
Principles of JIT
Identify the causes of JIT wastes
JIT manufacturing key activities and its features
JIT implementation and its draw back.
Continuous improvement
The primary causes of inventories
Schedule released and planned areas