Effective Production Planning, Scheduling and Control

• Achieve faster responses & on time delivery to customers
• Obtain better understanding of the planning/scheduling processes and best practices
• Learn how lean manufacturing & a flexible system can impact on planning and scheduling
• Utilize major applications of production planning & control methods used today
• Identify manufacturing operation process, layout, systems design & redesign
• Forecast the management demand
• Acquire final assembly scheduling & sequencing techniques
• Implement material planning process
• Integrate the Master Production Schedule with manufacturing operations
• Discover new facility, capacity planning & control techniques

CONTENT

Elements of Production Planning Operations, Scheduling and Controls

• Purpose & advantages of production planning, order sequencing, production scheduling, control, manufacturing operation process
• Sources of production control
• Characteristics of modern manufacturing management
• MRP II process & Lean manufacturing
• Symptoms & problems of poorly designed systems
• Schedule instability: causes & remedies
• Production planning procedure of a job order concern
• Information integration & workflow
• Types of information flow in PPC
• Control of Resources - material, labor, expenses, process control

Master Production Scheduling (MPS)

• Forecasting & sales order management
• Master production scheduling (MPS) activity
• Business planning
• Aggregate planning
• Team Activities: Owning your dream car
• Components of the MPS
• Link between MPS & MRP
• Purchasing supplier link in MPS/MRP
• Planning bill of materials
• Final assembly scheduling

Production & Operation Planning

• Sales order & work order balancing
• Bills of Materials
• Engineering Change Management
• Line Efficiency & improvement

Production Scheduling & Technique

• Scheduling objectives
• Job scheduling
• Forward/Back scheduling
• Input/Output control
• Dispatching rules - FIFS, SPT etc

Job Planning & Scheduling

• Job flow procedure
• Rough cut capacity planning
• Annual production plan
• Sequencing
• Scheduling Techniques
• short term scheduling
• short interval scheduling
• Participants to discuss on Scheduling Problems and Group Presentations
• Determination of capacity

Capacity Requirements Planning

• Types of capacity planning
• Factors affecting facility & capacity planning
• Optimizing the use of capacity
• Capacity planning & control techniques
• Finite & infinite capacity techniques
• Define work centres or stations & cost centres
• Case Study on decision tree analysis
• Managing schedule changes & loading
• Procedures for control schedule changes - policies & rules
• Formulate performance indices to measure changes
• Establishing feedback & communication system
• Understanding of JIT Manufacturing

Materials Planning & Inventory Management

• Materials Requirement Planning (MRP II)
• Independent and dependent demands
• Materials planning process
• Inventory planning involving management and control
• Finished goods inventories control

Lean Manufacturing

• Overview of Lean and its history
• Understand values and wastes in our organization
• Kanban Pull system and how to use it for scheduling
• E-Commerce solutions to improve your workflow
• Lean success stories

Utilizing Theory Of Constraint (Toc) For Planning

• What is TOC?
• Bottleneck and non-bottleneck resources
• Generic TOC principles
• Drum-buffer-rope (DBR) scheduling

Initiating The Planning & Control Activities

• Forecasting for production/manufacturing:
• Demand & demand management
• The nature & importance of forecasting
• Determining forecast accuracy
• Forecasting techniques
• Statistical analysis
• Moving averages
• Exponential smoothing
• Trends and seasonality
• The accuracy & monitoring of forecasts

Manufacturing Systems Design

• Relationship between production planning & control and manufacturing systems
• Integrating new technologies

Just-in-Time Manufacturing Strategy

• JIT production: set up time reduction, Kanban operation, small lot production
• Total quality control: quality at the source & zero defect
• JIT vs MRP II
• Push & pull manufacturing strategies
• Implementation of JIT with manufacturing resource planning

FOR WHOM:

Operation/Production Managers, Technicians, Machine Operators, Supervisors, Directors, and others who are involved in the day to day activities in the manufacturing sector.

TRAINING METHODOLOGY

The training methodology combines lectures, discussions, group exercises and illustrations. Participants will gain both theoretical and practical knowledge of the topics. The emphasis is on the practical application of the topics and as a result participant will go back to the workplace with both the ability and the confidence to apply the techniques learned to their duties.

This course is available in the following locations:
Nigeria - $3000
Ghana    - $6000
Rwanda - $7000
UK - $8000
USA - $8000