Professional Documents
Culture Documents
Production Planning
& Inventory Control
Forecasting
Aggregate Planning
Inventory Management
Scheduling
Production Planning & Master Production
Scheduling (MPS)
Material Requirements Planning (MRP)
Capacity Planning
Just-in-Time (JIT) & Lean Manufacturing
2
Introduction to
Production Planning &
Inventory Control
Production System
Input (4Ms):
Money
Man
Materials
Machine
Transformation
Output:
Product or Service
Production System
Other Resources
Suppliers
Raw
Material
Inv.
Transformation
Work-In-Process
(WIP)
Finished
Goods
Inv.
Customers
Objectives of PIM:
PIM Functions
Production Planning
Decisions
Strategic Planning
Top Management
Long-Range Planning Horizon:
>18 months 10 years
Long-Range Planning Activities:
Business Forecasting
Product & Sales Planning
Production Planning
Resource Requirements Planning
Financial Planning
Production Planning
Decisions (Contd)
Tactical Planning
Middle Management
Medium-Range Planning Horizon: 1-18
months
Medium-Range Planning Activities:
10
Production Planning
Decisions
Operational Planning
11
Production Systems
Dimensions
Levels
Physical Organization
Key Resources
Order Initiation
Product Authorization
Product Variety
Product Volume
Fabrication / Assembly
Structure
Time Horizon
Physical Organization:
4 basic layout types
(1) Process Layout:
Used when many different products
are produced & there is a need for
skilled expertise at production
processes.
A greatest flexibility to produce a
variety of items
Low equipment use
Long throughput times
13
Physical Organization
(2) Product Layout:
Used for repetitive manufacturing where
demand is large enough to economically justify
the dedication of equipment to a single product.
Production processes are laid out in a
sequential manner so that product visits each
area, one right after the other.
Equipment is designed to have similar
production rates at each stage.
In a high volume environment, product layouts
are very efficient and typically have small
throughput times.
14
Physical Organization
(3) Cellular Layout:
Attempt to partition large facilities into
smaller cells designed to produce a
family of related parts or products.
Similarity of machines/tooling or usage
in the same finish products.
Each cell is a simpler mini-factory, with
short materials moves and easier
coordination.
15
Physical Organization
(4) Fixed Position Layout:
Large projects such as constructing
a building.
16
Physical Organization
17
Physical Organization
Characterist Produ Proce Cellular Fixed
ic
ct
ss
Skill Level
Low
High Mixed
High
Unit
Low
High Low
High
Production
Cost
Equipment
Utilization
High
Low
Moderat
e
High
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Low
Moder
ate
Key Resources
Capital Intensive:
High-cost machines/equipments
Run multiple shifts & employ adequate labor
to keep the process running.
Increasing capacity takes a long time and is
very expensive.
Often the majority of cost is fixed and thus it
is expensive to have the equipment idle.
Capacity of all resources is maintained at a
higher level to ensure optimal use of the
bottleneck.
19
Key Resources
Labor Intensive:
Automobile
Furniture
Consumer electronics
Textiles
Foods
Chemicals
Pharmaceuticals
21
Strategy:
Emphasizes immediate delivery of good quality,
reasonable priced, off-the-shelf, standard items.
Sets target levels for the number of units of each
product to keep on hand at all times.
Makes sense when delivery response time is a key
competitive factor.
Stocking allows us to schedule production in
advance and to coordinate the delivery of R/Ms with
the production schedule.
Large inventories of F/Gs (due to the need to provide
a variety of size, colors & features)
Require investment capital & storage space
Run the risk of damage & obsolescence
22
Strategy:
To provide the technical ability to produce specialty
products
Inventories of F/Gs are not maintained
Items are only produced after they have been ordered.
Some components are custom designed for the
customer.
Materials are often purchased after the order is placed.
Long Lead Time
Make-to-Order is appropriate when
The system can respond quickly to customer requests
Products have a high degree of customization
Shelf life of products is short because of changing
customer tastes or product spoilage.
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24
Production Authorization
25
Production Authorization
Push System:
26
Production Authorization
Pull System:
27
28
30
Product Structure
31
Time Horizon
(Static vs. Dynamic
Environments)
Production Process
Design
Flow Shop
33
Flow Shop
34
Continuous Flow
2.
35
36
Production Process
Design (Contd)
Job Shop
37
Job Shop
38
Job Shop
39