ECO EXECUTION AND CONTROL OF OPERATIONS Highlights

Manufacturing Planning Manufacturing environments, process types & layouts Influence of manufacturing process choices on execution and control of operations choices Use of material requirements planning (MRP)-based and lean/JIT-based execution systems Defining Execution and Control Systems Mass and continuous production Batch and flow processes Rate-based and time-phased planning Push and pull principles Pull in lean/JIT production systems MRP-Based Scheduling Material requirements planning (MRP)-based vs lean/JIT-based scheduling Lead time components, back and forward scheduling, finite and infinite loading, sequencing and priority Theory of Constraints Scheduling TOC TOC scheduling techniques Drum, buffer, and rope in TOC scheduling Steps of the TOC scheduling process Lean/JIT-Based Scheduling Lean/JIT scheduling, production planning, and master scheduling Production leveling Heijunka and mixed-model scheduling Scope and Principles of Operations Control Goals of production and quality control MRP-based vs lean/JIT-based scheduling & control Three operational quality processes of the Juran trilogy Production Activity Control: MRP-Based Flow manufacturing and batch production Input/output control, job sequencing, dispatch list Operation overlapping, lot splitting and size reduction Production Activity Control: Lean/JIT Differences between MRP- and lean/JIT-based production control systems Heijunka and the kanban control system Cycle time and one-piece flow Inventory Management Issues Inventory location systems Accounting classification and accuracy of inventory valuation Vendor-managed inventory Worker Development, Participation / Involvement Job enrichment and enlargement, self-directed work teams, employee empowerment, performance appraisal and rewards, suggestion programs Quality circle and kaizen circle activities Cost Control Product cost accounting (direct and manufacturing overhead costs) Job-order and process costing Absorption and variable costing Activity-based costing vs product costing Direct and manufacturing overhead costs Actual and standard costs Control of Quality Sporadic and chronic quality problems Attribute or variable acceptance sampling Special and common causes of variation Process capability and product specifications (Process capability indices Cp and Cpk) The Seven Basic Quality Tools Control charts, to analyze statistical process control Pareto charts, check sheets, histograms, scatter charts, cause-and-effect diagrams, and process maps Six Sigma DMAIC Activities of the DMAIC phases Formulating and testing hypotheses PDCA Cycle PDCA cycle & lean/JIT culture Visual management and nemawashi (consensus building) in the PDCA cycle A3 Problem Solving A3 thinking and problem solving Visual communication and management in A3 problem solving A3 report Design Principles Customer lead time and decoupling point Tradeoffs in job design between intermittent and mass production processes Relationships with suppliers and customers Global principles included in the core goals of PQCDSM in lean/JIT organizations Hoshin planning Design Techniques Flow through a supply network Multiple- and single-sourcing Outsourcing, assessment of supplier capability Use of Pareto analysis by cross-functional customer/buyer teams Quality function deployment and concurrent engineering Design of experiments Five Ss, visual management, and workplace layout

APICS develops the internationally recognized education programs CPIM - Certified in Production & Inventory Management and CSCP - Certified Supply Chain Professional. The PMI PRODUCTION MANAGEMENT INSTITUTE is APICS authorized educational partner and trains and supports the APICS education for major industrial organisations including 3M, Adidas, Altana, Baxter, BASF, Biogen Idec, Bosch, Celestica, CSL Behring, DOW, Delphi, Dupont, Dynamit Nobel, Eurocopter, Faurecia, Flextronics, Hettich, IBM, Johnson Controls, JT International, Lear, Merck, Novartis, Philips, Robust Plastik, Roche, Rolls Royce, Sanofi-Aventis, SAP, Siltronic, Synthes, Tenneco Automotive, Tridonic, TYCO, Valeo, Volvo, Wavin, Weleda.
PMI PRODUCTION MANAGEMENT INSTITUTE GmbH, Lena-Christ-Str. 50, 82152 Planegg, Germany Tel. +49 (89) 857 61 46, Fax +49 (89) 859 58 38 office@pmi-m.de, Internet: www.pmi-m.de