Introduction & Overview

Paulus Tangkere Production Planning & Inventory Control Session 1

Course Objectives

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To understand the various components and functions of production planning and control such as work study, product planning, process planning, production scheduling, Inventory Control. To know the recent trends like Manufacturing Requirement Planning (MRP II) and Enterprise Resource Planning (ERP). Identify different strategies employed in manufacturing and service industries to plan production and control inventory. Measure the effectiveness, identify likely areas for improvement, develop and implement improved planning and control methods for production systems.

Syllabus
1. 2. 3. 4. 5. 6.

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Introduction of Production System Production and Inventory Control Production Planning Production-Distribution System Design Master Production Scheduling Design of Production Planning and Control Systems

References

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Bedworth, D.D. and J.E. Bailey, Integrated production Control Systems, Second Edition, John Wiley, 1987 Francesco Jovane & Engelbert Westkmper David Williams, The ManuFuture Road, Springer, 2009. Other references.

Methodology
Lectures Readings Case Studies Assignments

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Grading
Midterm Final Others : 35% : 35% : 40%

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Assignments individual and group Class Participation Course Summary Quiz pretests and posttests

Group
Consists of max. 5 students Responsibilities
Distributed Team Personal/Individual

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Internal communications

Communication
pt4bu@yahoo.com

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Manufacturing Planning & Control System

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Introduction of production System

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Types and characteristics of production systems Demand Forecasting: Long and Shortterm demand forecasting methods, Regression analysis and smoothing methods, Estimation of trend, cycle, and seasonality components, Analysis of forecast error and computer control of forecasting systems.

Production and Inventory Control

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Progress control through records and charts. Types of inventories, Inventory Classification. Inventory Control under constraints Economic lot (batch) size. Trends in purchasing and store keeping, JIT production MRP II, comparison of Push & Pull systems, ERP.

Production Planning

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Aggregate Planning, MPS, Material Resource Planning, Selection of material methods, machines & manpower. Routing, Scheduling and Dispatching and its sheets & charts, Production Line Balancing.

Production-distribution system pt design

Plant location and capacity scheduling, Multiple plant production facility design. Aggregate planning and master production scheduling, Aggregation techniques, Aggregate capacity scheduling, Disaggregation of aggregate plan.

Master production scheduling pt

Analytical and computer integrated solution techniques, Operations scheduling and control: Basic sequencing and scheduling techniques, Dispatching rules, Progress chasing and Updating of production schedules.

Design of production planning pt and control systems

System design for continuous and intermittent production systems, Integration of master production, Material requirement and Shop scheduling systems.

Decision Making in Production pt

What to produce product planning and development, including product design. How to produce process planning, material planning, tool and equipment planning Where to produce facilities planning, capacity planning, subcontracting planning When to produce production scheduling and machine loading Who will produce manpower planning How much to produce quantity planning, economic batch size, etc.

Production Critical Decisions

Managing quality Design of goods and services Process and capacity design Layout design Human resources Location strategies Supply-chain management Inventory management Scheduling Maintenance

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