manufacturing planning & scheduling

8/8/2019 Manufacturing Planning & Scheduling

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Manufacturing Planning &

Scheduling

N.K.Agarwal


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PPC isthe organisation and planning of

manufacturing process

PPC

Co-ordinatessupplyand movement of materialsand labour

Ensures economic and balanced utilisation of machinesand

equipments,and

Otheractivitiesrelated with production

To achieve the desired manufacturingresults

Production Planning & Control(PPC)


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Production Planninginvolves

Formulation

Co-ordination,and

Determination ofactivities

In a manufacturingsystem

Production Controlinvolves

Process of maintainingabalance between variousactivities

involved in production planning providing

Most effective and efficient utilisation ofresources

Production Planning & Control(PPC)


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Production Planning

The function ofthe managementthat decides

The resourcesthe firm willrequire forits future

manufacturing operations,and

Allocatingthese resourcesto produce the desired outputin

required amountatleast cost


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Production planning prepares

Procurement plans formaterialsand personnel,

Establisheswork proceduresand control, Preparesand issuesworkauthorisation,establishes finished

goodsinventory control,and

Maintainsalternative plans ofaction

Production Planning-Procedures


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Categories of production planning procedures

Routing

Scheduling,and Loading

Production Planning-Procedures


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Routing means determination of path orroute over

which each piece isto travelin beingtransformed

from raw materialinto finished product Routinggenerallyinvolvesthe following

Whetherto make/buy

Form and shape ofthe material

Division ofworkto be done into operations

Production Planning-Routing


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Choice of machines/ work centers on which each operation

should be done and its duration

Sequence in which operationsare to be performed

Division of operationsinto work elements

Choice ofspecialtooling

Economic lotsize of production orderquantity

Estimation ofamount ofscrap



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Schedulingis

Decidingwhen and where each operation in a production

processisto be executed,and

Establishment oftime table atwhichto begin and/or

complete each event oroperation involved in a procedure

Production Planning-Scheduling


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Developed byreviewing market forecasts, customer

orders,inventorylevels, facilityloading & capacity

information regularly Plan for future production of end items overshort

range planninghorizon

An importantlinkbetween production and marketing

Master Schedule


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F

unctions of MPS

Translatingaggregate plansinto specific end items

Evaluatingalternative masterschedules

Generating materialrequirement Generating capacityrequirement

Facilitatinginformation processing

Maintaining valid priorities

Utilising capacity effectively


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MASTER PRODUCTION SCHEDULE- FLOW CHART

FORECAST & CUSTOMER

ORDERS

AGGREGATE PLAN

TENTATIVE MPS

TRIALFIT ON

MRP SYSTEM CRP SYSTEM

ARE

MATERIALSADEQUATE ?

ARE

CAPACITIESADEQUATE ?

FIRM MPS

TO MRP & CRP SYSTEM

DOMESTIC &INTERNATIONAL

REVISE MASTER

SCHEDULE

REVISE MASTER

SCHEDULE

END PRODUCTS &

SERVICE PARTS /

SPARE PARTS

CAPACITY

REQUIREMENTPLAN (CRP)

YESYES

NO NO


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MPS Environment

Make to stock

Production bythe companyin batches

Carries finished goodsinventory formost ofthe end items

Mostly consumerproducts

Orders from warehouses mostly

Lotsizes of ordersbased on economics

Efforts to prepare MPS are relatively less


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Make to order

Companies do not carry finished goodsinventory

Builds customerordersas needed

Customers expected to wait forthe design & manufacturinglead time

Example: Buildings, Jewellary making,Ship building

Lotsize and numberof products depends upon customer

orders

Many product designs, productsand ordersto be included

Efforts required to prepare MPS are more

MPS Environment


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Assemble to order Typicalwith verylarge numberof possible end items made from

combination ofbasic componentsand sub-assemblies

Customerdeliverytimes often lessthan totallead times

Flexibility maintained in manufacturing Basic componentsand sub-assemblies produced

Finalassembliestaken up onlyagainst customerorder

Example:Automobile manufacturing,Forkliftswith

differentspecifications

End items notscheduled Schedule unitsstated in planningbills of materials

Common partsand options form the MPS planningbill

MPS Environment


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Objectives

To plan newwork orders on the basis ofspare capacity

available

To balance the workload in a plant

To maintain delivery promises

To checkthe feasibility of production programmes

Production Planning-Loading


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PPC-Production Control

Production Controlisthe procedure

To regulate an orderly flow of materials,and

Co-ordinate various production activities

To accomplishthe objective of producingthe desired

item

In the right quantity of desired qualityatthe required

time bythe bestand the cheapest method

To attain highest efficiencyin production


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Properco-ordination ofthe operation of varioussections/

departmentsresponsible forproduction

To ensure timelysupply ofraw materialatthe desired place

and of prescribed qualityand quantityto avoid delaysin

production

To perform inspection ofsemi finished and finished goods

and use of quality controltechniquesto ensure

manufactured goods meetingrequired specifications

Also responsible forproduct design and development


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Production Control- Levels

Three levelsin production control

Programming

Planningthe output of product forthe factoryasawhole

Ordering

Planningthe output of components from suppliersand

production departments

Dispatching

Considers each processing departmentin turn and plans

the output from the machines,toolsand otherworkcentersso asto complete the orderby due date


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Orderingis

Process of placing orders,also known aswork orders, to

the suppliersand the processing departments forthe

materialsand otherparts needed to manufacture theproduct,and

To arrange the ordering quantityand deliveryschedule in

suchaway

Thatallitemsare delivered in time to meetthe

production programme

Production Control- Ordering


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The decision ofassigning variousjobsto different

machinesisknown asDispatching

Functions To checkthe immediate availability of materials

Ensuringavailability ofall production and inspection aids for

use

Obtain appropriate drawingsand specifications

Collatejobs, operation layouts,routine etc.withthe design

Production Control- Dispatching


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Processinginformation orinspection schedule

Assign workto definite machine,work place and men

Issue necessary materialsand tools etc.to the required point

foruse

Issue production note indicatingthe startand finishtime of

the work

Inform progressregardingstart ofwork

Instruction to startthe work

Maintain all production records

Production Control- Dispatching


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Follow-up/expediting orprogressingis checking

production activitiesso that production maybe

carried outas perplan

Involves measurement of outputagainst plan,analysis of

performance forshort-fallsand following up the line

managementto apply corrective action

The chaserisresponsible forobservingthatany

detailwhichis overlooked ornot properly executed issetright

Production Control- Follow - up


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Schedulingbecomes complex due to

Delivery dateshave to be promised forwork ordersagainstcustomers orders

Production lotstend to become small & manyrequire

machine change over

Possibility ofassigning / reassigningworkers & machinesto

variouswork orders Schedulesto be specific and detailed machine wise to bring

orderliness

Scheduling of Process Focused

Production Systems


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Scheduling of

Product - Focused System Relatively fewerstandard product designs

Production usually on produce to stock & sellbasis

Finished goodsinventoriesare maintained Production rates ofindividual products exceed their

demand

Muchless pre production planning concerningroute sheets,job

instructions, process plansand product designs

Schedulesbased on economic production runs forproductswithoutfirm delivery commitments

Majorscheduling concernsare

Timing of production line change over

Length of production runs


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Reduces cost of production by minimisingwastage of

materialand economic utilisation ofresources

Leadsto lowerinvestmentby means of efficientandbalanced utilisation ofresources

Promotes employee morale byavoidingallsorts of

bottlenecks

Enhances customersatisfaction and confidence

PPC - Importance


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MPS and Shop Floor Planning &

Control

MPSand shop floorplanning & controlresultsin Lowinventorylevels,

Minimise the manufacturing cycle time,

Full utilization of production services,and

Helpsin the development of positive customerrelations

By meetingthe promised delivery dates


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References Production Operations Management :

Aswathappa / Bhat

Modern Production / Operations Management:Buffa / Sarin

Operations Management :

Donald Waters

Manufacturing Planning & ControlSystems :

Vollman / Bery / Whybark


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Thank You


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PPC - Objectives

Determiningthe nature and magnitude of variousinput factorsto manufacture the desired output

To co-ordinate labour, machinesand equipmentin

the most effective and economic manner

Establishingtargetsand checkingthese againstperformance

Ensuringsmooth flow of materialsby eliminating

bottlenecksin production

Utilisation of underemployed resources

To manufacture the desired output ofright qualityand

quantityatrighttime


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Production Planning-Objectives

Systematic co-ordination and regulation of variousactivities

To maintain properbalance ofthe activities for

efficient production

Determination ofraw materials, machines, equipmentetc.and otherinputs fordesired output

Anticipation ofbusiness changesand reactingto

them in propermanner

To have optimum usage orresourceswith optimum

costand time

To provide alternative production strategiesin case of

emergencies


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Varioustypes of proformasto record details of

production processat differentstagesalso to be

designed

In manufacturing plants,routing ofan ordercarried

out usingRoute Sheets



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Route Sheet

ManufacturingOrder no.

Drawing no. Date of completion

Description of

the item

Remarks

No. of pieces on

order/Economic

lot size

Spoilage

allowance

Total items to

be produced

Material description

Purchase Order no.

Time/ Piece

Tool Description

Quality of material allotted.

Stores requisition no.

Due date.

Setup time/lot operation no.

Time allowance


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Objectives of Production control

Provision ofraw materials, equipment, machinesand labour

To organise production in conformitywiththe demand

forecast

Ensure utilisation ofresourcesin the best possible manner

suchthatthe cost of production is minimised and delivery

date is maintained

Determination of economic production runswitha viewto

reduce the setup costs



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Production Control- Techniques

Programming: Objectives

Reliable deliveryto customers

Even loading ofthe plant

Even loading ofthe labourin total man -hours perweek

Efficient use of capital

Lack of production programmingin any

manufacturingsystem resultsin late deliveryto

customers


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SCHEDULING SERVICES

ECONOMICACTIVITIES INWHICH PRIMARYOUTPUT IS

NEITHERA PRODUCT NORA CONSTRUCTION

VALUE ISADDED TO THISOUTPUT THAT CANNOT BE

INVENTORIEDLIKE CONVENIENCE, COMFORT,SECURITY,AND THEOUTPUT IS CONSUMEDAS PRODUCED

TRANSPORTATION

UTILITIES

COMMUNICATIONS

FINANCE,BANKING, INSURANCE, POST & TELEGRAPH


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SERVICE OPERATIONS

SERVICESYSTEMS

DONOT HOLD INVENTORIES

DEMANDON THEM HIGHLY VARIABLE

OPERATIONSLABOUR INTENSIVE PRIMARILY PERFORMED THROUGH PERSONNEL

ASSUCH, PERSONNELSCHEDULING BECOMES COMPLEX


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SERVICE OPERATIONS

ALSOKNOWNASNON-MANUFACTURING OPERATIONS, CAN

BE CLASSIFIEDAS

STANDARDSERVICES

CUSTOMERSERVICES CLASSIFICATIONACCORDING TO THEDEGREEOF

STANDARDISATIONOF THEOUTPUTSAND THE PROCESS

PERFORMEDBY THESERVICESYSTEM


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SERVICE OPERATIONS

STANDARDSERVICES

SYSTEMS MORELIKE PRODUCT-FOCUSSED MANUFACTURING

SERVICESSTANDARDFOR MOST CUSTOMERS

PROCESSONCEBEGUN CARRIED THROUGH TOCOMPLETIONWITHOUT MUCHDELAY

SIGNIFICANT DIFFERENCEWITH PRODUCT-FOCUSSED

MANUFACTURING BEING THAT SERVICES PRODUCED

ACCORDING TO CUSTOMERORDERRATHER THANFOR

FINISHED GOODS INVENTORY

TRNASPORT COMPANIES,FAST FOOD

RESTAURANTS, POSTALSERVICES,AIRLINES

SOPHISTICATEDSCHEDULING SUCHASON-LINE

COMPUTERBASEDSCHEDULING SYSTEMS USED


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SERVICE OPERATIONS

CUSTOMERSERVICES SYSTEMSLIKE JOBSHOPSANDHENCESCHEDULING MUCH

LIKE JOBSHOPS

SMALLSERVICESLIKEADOCTORS CLINIC,SMALLRETAILERS,LOCAL TRANSPORT COMPANIES

NOFORMALSCHEDULING SYSTEMSEMPLOYED

SIMPLESCHEDULING SYSTEMSSUCHASAPPOINTMENTSCHEDULES, TOKENSYSTEM,FIRST-COME-FIRST-SERVICEETCUSED TOASSIGN PRIORITIES TO CUSTOMERS

PART TIMEWORKERSANDSTAND-BYEQUIPMENT FREQUENTLYUSEDDURING HIGHDEMAND PERIOD

HOSPITALS USE MORESOPHISTICATEDSCHEDULING SYSTEM

INCLUDINGA MOST CRITICALNEED CRITERIA ;FIRST-COME-FIRST-SERVED


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SCHEDULING PERSONNEL IN

SERVICES PERSONNELSCHEDULESDEVELOPED TOALLOWSYSTEM

CAPACITIESWHICH MATCH THE CUSTOMERDEMAND SYSTEM CAPACITY VARIEDBY VARYING NUMBEROF PERSONNEL TO

WORKDURING EACHHOUROF THEDAY

PART TIME PERSONNEL MAYBEEMPLOYEDDURING PERIODSOFPEAKDEMAND

FOREMERGENCYSERVICESLIKEFIREOR POLICE,SCHEDULINGDONEFOR 24 HOURFULL CREW COVERAGE

DURING PEAKDEMAND PERIODS,OFF-DUTY PERSONNEL CALLED INAND COMPENSATEDWITHOVERTIME PAYMENT OR TIME-OFFS

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