Professional Documents
Culture Documents
Trainers:
HakeemUrRehman
&
Sajid Mahmood
Simple Sustainable Solutions 1
Production Planning & Control
Outline:
DAY1:
o What is Production Planning & Control (PPC)?
o Forecasting Methods & Its Applications
o Understanding Data Patterns & Its Methods
DAY2:
o Aggregate Production Planning (APP)
o Inventory Management
DAY3:
o Master Production Scheduling (MPS)
o Material Requirement Planning (MRP)
Why Forecasting?
Forecasting:
Principles of Forecasting:
1. Forecasts Are Almost Always
Wrong (But They Are Still Useful)
Qualitative Techniques
Quantitative Techniques
o Market surveys
o Delphi method Time Series Models: Future Causal Models: Future is a
o etc. is a function of time function of any other factors
o Moving Average other than time
o Weighted Moving Average o Linear Regression
o Exponential Smoothing o Multiple Regression
o Linear Regression
o etc.
Simple Sustainable Solutions Hakeem-Ur-Rehman & Sajid Mahmood 6
Production Planning & Control
Quantity
Time
Time
(c) Seasonal Pattern: Data exhibit a regularly (d) Cycle: Data increase or decrease over time
repeating pattern (Data patterns created by economic fluctuations)
Quantity
Quantity
400
200 Demand
0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52
Time (Weeks)
Is Trend Present? Run Linear Regression to test in the model = 0 + 1 t +
( )2
=
= 100
Smaller the Error Performance Measure (i.e MAD, MSE, MAPE) better the method.
Excel Solver can be used to determine the values of the model parameters.
Holts Linear Exponential Smoothing: The trend adjusted forecast consists of two
components.
Smoothed factor (i.e. Level)
Trend factor
Level:
Ft +1 Lt Tt
Trend:
Adjust the Level Lt , and
Initial Values: the Trend Tt in each period
Day1: Review
Why Forecasting?
What is Forecasting?
Forecasting Methods
o Smoothing Techniques (i.e. Averaging Techniques)
o Linear Trend Techniques
o Decomposition Technique
Outline:
DAY1:
o What is Production Planning & Control (PPC)?
o Forecasting Methods & Its Applications
o Understanding Data Patterns & Its Methods
DAY2:
o Aggregate Production Planning (APP)
o Inventory Management
DAY3:
o Master Production Scheduling (MPS)
o Material Requirement Planning (MRP)
A poor aggregate plan can result in lost sales, lost profits, excess inventory, or
excess capacity
Simple Sustainable Solutions Hakeem-Ur-Rehman & Sajid Mahmood 20
Production Planning & Control
Aggregate
Planning
Goal: Specify the optimal combination (tradeoff) of Production rate, workforce level,
overtime production, subcontracting (i.e. outsourced capacity), inventory / backlog to
maximizes the firms profit over the
Simple Sustainable Solutions
planning horizon
Hakeem-Ur-Rehman & Sajid Mahmood 22
Production Planning & Control
Estimated labor hours per installation: Estimated supply costs per installation:
0.4* 2 + 0.4 * 3 + 0.2 * 4 = 2.8 hours 0.4 * $15 + 0.4 * $90 + 0.2 * $155 = $73
ABC expects (i.e. forecasted) total installations for the next three months to be 150,
175, and 200, respectively.
Estimated Resource Requirements at ABCs Electrical
Advantages: Advantages:
o Stable output rates and workforce o Investment in inventory is low
o Labor utilization in high
Disadvantages:
o Greater inventory costs Disadvantages:
o Increased overtime and idle time o The cost of adjusting output rates
o Resource utilizations vary over and/or workforce levels
time
Simple Sustainable Solutions Hakeem-Ur-Rehman & Sajid Mahmood 27
Production Planning & Control
Labour hrs. Req. per month = (Labour hr. per unit) * (Months forecasted
demand)
# of workers Req. per month = (Labour hrs. Req. per month ) / (Working hrs. per
month per employee)
Cost for a period = Output Cost (Reg.+OT+Sub.) + Hire/Lay off cost + Inventory
cost + Back order cost
Simple Sustainable Solutions Hakeem-Ur-Rehman & Sajid Mahmood 28
Production Planning & Control
Dependent Demand A
B(4) C(2)
1. CARRYING COSTS: Cost of holding an item in inventory; Vary with the level
of inventory and the length of time an item is held
Carrying costs include: Rent, Heating, cooling, lighting Security, Record
keeping
3. SHORTAGE COSTS
Temporary or permanent loss of sales when demand cannot be met because of
insufficient inventory
Customer dissatisfaction and loss of goodwill
For internal demand, shortage can cause work stoppage or create delays
= +
= + 2 + 2
Day2: Review
Inventory Management
o What is Inventory?
o Inventory Costs
o What is Inventory Management?
o ABC Classification
o Inventory Control Systems
o EOQ Model
o Safety Stock
Outline:
DAY1:
o What is Production Planning & Control (PPC)?
o Forecasting Methods & Its Applications
o Understanding Data Patterns & Its Methods
DAY2:
o Aggregate Production Planning (APP)
o Inventory Management
DAY3:
o Master Production Scheduling (MPS)
o Material Requirement Planning (MRP)
In Reality
o Demand and Production numbers in the
master schedule are unlikely to match the
sales and operations plan exactly.
B(4) C(2)
When to Use MRP?
Dependent and discrete items
D(2) E(1) D(3) F(2) Complex products
Job shop production
Assemble-to-order environments
Independent demand is uncertain.
Dependent demand is certain.
Time-phased BOM: An assembly chart shows the lead time required to manufacture an item.
Assume Lead time for each item =1 week
MRP
Matrix:
ANY QUESTION?