MP&Control-Course handout-MM ZG533

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
WORK INTEGRATED LEARNING PROGRAMMES

Digital Learning
Part A: Course Design
Course Title Manufacturing Planning & Control
Course No(s) MM ZG533
Credit Units 5
Credit Model
Content Authors
Course Objectives
No
CO1 The course teaches the students about the major elements and concepts in manufacturing
planning and control
CO2 The course provides knowledge about different tools, techniques and systems that facilitate
manufacturing planning and control
Text Book(s)
T1 Chase, R.B., Shankar R., Jacobs, F.R, “Operations and Supply Chain Management”, 14 th ed.,
Tata McGraw-Hill, New Delhi, 2014
Reference Book(s) & other resources

R1 Krajewski, L.J., Ritzman, L.P., Malhotra, M.K., Srivastava, S.K., “Operations Management:
Processes and Supply Chains”, 9th ed., Pearson Education, 2010
Content Structure
Lecture Course- Course-sub- Topics Title Contact Session
No. module title module Number
1 Strategy, Productivity and Productivity, nature of 1
Products, and Manufacturing manufacturing, modern
Capacity Management management, performance
measures
2 Functions in Product design, process planning, 2,3
Manufacturing, determining number of equipment
manufacturing
process planning
3 Processes- Methods Analysis Graphical tools for analyzing 4,5
Planning & and Work work methods, Methods for work
Design for measurement measurement, time study, PMTS
4 Production Understanding Different types of processes, 6,7
Processes and Little’s Law, Make to stock, make
Material Flow to order and assemble to order
systems, material flow
5 Plant layout and Different types of layouts, 8,9
design quantitative methods for layout
planning, criteria for assessing
layouts, activity relationships in
layouts
6 Plant layout and Machine cells in manufacturing, 9
material handling material handling concepts, types
of material handling equipment
7 Material handling Different types of material 10
handling systems and equipment,
method for selecting appropriate
material handling system, storage
equipment
8 Line Balancing Precedence diagrams and line 11
balancing, measures of
performance
9-10 Supply & Forecasting Role of forecasting in predicting 12, 13, 14
Demand demand, different forecasting
Planning methods, quantitative and
qualitative forecasts, time series
models in forecasting, moving
average, exponential smoothing,
regression, forecast errors,
capacity planning
11 Capacity Planning Different strategies for capacity 15, 16
and Aggregate planning, aggressive and risk
Sales and averse strategies, decision trees for
Operations capacity planning, pure strategies
Planning in aggregate sales and operations
planning
12-13 Inventory The role of inventory in 17,18
Concepts and manufacturing, costs of inventory,
Models EOQ, inventory models under
uncertainty
14 MRP and ERP Dependent demand systems, 19,20
Systems material requirements planning,
Lot sizing, capacity requirements
planning, implementation issues
15-16 Control Current Introduction to Lean 21, 22
Strategies Approaches in Manufacturing, basic principles
Manufacturing and tools, JIT, Pull, etc., Theory of
Constraints, financial and
operational measurements
Learning Outcomes:
After completing this course the student should be able to:
No Learning Outcomes
LO1 Build a strategy to develop and manufacture a product
LO2 Draw up a list of requirements, evaluate and design the strategy, process and facilities for
manufacturing the product
LO3 Implement a forecasting, demand management, aggregate operations planning system
LO4 Design and implement an inventory management system.
LO5 Identify the need and implement appropriate controls and implement principles of lean
manufacturing and theory of constraints as dictated by organizational goals and strategy.
Part B: Contact Session Plan
Academic Term FIRST SEMESTER 2016-2017

Course Title Manufacturing Planning& Control
Course No MMZG533
Content Developer PAVAN POTDAR
Glossary of Terms:
1. Contact Hour (CH) stands for a hour long live session with students conducted either in a physical
classroom or enabled through technology. In this model of instruction, instructor led sessions will be
for 20 CH.
a. Pre CH = Self Learning done prior to a given contact hour
b. During CH = Content to be discussed during the contact hour by the course instructor
c. Post CH = Self Learning done post the contact hour
2. RL stands for Recorded Lecture or Recorded Lesson. It is presented to the student through an online
portal. A given RL unfolds as a sequences of video segments interleaved with exercises
3. SS stands for Self-Study to be done as a study of relevant sections from textbooks and reference
books. It could also include study of external resources.
4. LE stands for Lab Exercises
5. HW stands for Home Work will consists could be a selection of problems from the text.
Contact Hour 1: Productivity and Manufacturing Management
Time Type Sequence Content Reference
Pre CH RL1.1 RL1.1.1 = Module-1 T1
RL1.1.2 = Module 1.2 - Manufacturing Context
RL1.1.3 = Module-3
RL1.1.4 = Module-4
RL1 1.1.5 = Module-5
During CH1 CH1.1 =Introduction to course

CH CH1.2 =Method of course a devaluation scheme
CH1.3 =Lecture summary
CH1.4 =Example problems on performance metrics
Post CH SS1
Post CH HW1
Post CH LE1
Post CH QZ1
Contact Hour 2: Functions in Manufacturing, manufacturing process planning
Pre CH RL2.1 RL2.1.1 =Module-1 T1

RL2.1.2 = Module-2
RL2.1.3 = Module-3
RL2.1.4 =Module-4
During CH2 CH2.1 =Business strategy T1

CH CH2.2 =Product development
process
CH2.3 = Product design
CH2.4 =Example on Breakeven
analysis
Post CH SS2
Post CH HW2
Post CH LE2
Post CH QZ2
Contact Hour 3: Functions in Manufacturing, manufacturing process planning

Pre CH RL3.1(same as RL2.1.1 =Module-1 T1

for contact RL2.1.2 = Module-2
hour 2) RL2.1.3 = Module-3
RL2.1.4 =Module-4
During CH3 CH3.1 =QFD

CH CH3.2 =Example on Process
planning-process sheets, operation
chart,
CH3.3 =Examples on Determining
processing capacity requirements
Post CH SS3
Post CH HW3
Post CH LE3
Post CH QZ3
Contact Hour 4: Methods Analysis and Work measurement
Pre CH RL4.1 RL4.1.1 = MPC_RL_3.1 T1

RL4.1.2 = MPC_RL_3.2
RL4.1.3 = MPC_RL_3.3
During CH4 CH4.1 =Lecture/topic summary T1

CH CH4.2 =Problem on activity and
methods analysis
Post CH SS4
Post CH HW4
Post CH LE4
Post CH QZ4
Contact Hour 5 Methods Analysis and Work measurement


RL4.1.2 = MPC_RL_3.5
RL4.1.3 = MPC_RL_3.6
During CH5 CH5.1 =Lecture/topic summary

CH CH5.2 =Examples on time study
CH5.3 =Example on sampling
studies
Post CH SS5
Post CH HW5
Post CH LE5
Post CH QZ5
Contact Hour 6: Understanding Processes and Material Flow
RL6.1.2 = MPC_RL_4.2
During CH6 CH6.1 =Lecture/Topic summary

CH CH6.2 =Example using
predetermined standard time
systems
CH6.3 =Discussion/examples on
MOST studies
Post CH SS6
Post CH HW6
Post CH LE6
Post CH QZ6
Contact Hour 7: Understanding Processes and Material Flow

RL6.1.2 = MPC_RL_4.4
RL6.1.3 = MPC_RL_4.5

CH CH7.2 =Examples on process flow
calculations, process design
Post CH SS7
Post CH HW7
Post CH LE7
Post CH QZ7
Contact Hour 8: Plant layout and design


RL8.1.2 = MPC_RL_5.2
RL8.1.3 = MPC_RL_5.3
RL8.1.4 = MPC_RL_5.4
RL8.1.5 = MPC_RL_5.5
Pre CH RL8.2 RL 8.2.1 =

RL 8.2.2 =
RL 8.2.3 =
RL 8.2.4 =

CH CH8.2 =Example on flow chart
and cell/layout design
Post CH SS8
Post CH HW8
Post CH LE8 Exercise on simulation using excel
Post CH QZ8
Contact Hour 9: Plant layout and material handling


RL9.1.2 = MPC_RL_6.2
RL9.1.3 = MPC_RL_6.3
RL9.1.4 = MPC_RL_6.4
RL9.1.4 = MPC_RL_6.5
Pre CH RL9.2

CH CH9.2 =Example on activity
relationships/systematic layout
planning
CH9.3 =Discussion/exercise on
creation of machine cells
Post CH SS9
Post CH HW9
Post CH LE9
Post CH QZ9
Contact Hour 10:Material Handling
Pre CH RL10.1 RL10.1.1 = MPC_RL_7.1 Lecture notes/ppt

RL10.1.2 = MPC_RL_7.2
RL10.1.3 = MPC_RL_7.3
RL10.1.4 = MPC_RL_7.4
RL10.1.5 = MPC_RL_7.5
RL10.1.6 = MPC_RL_7.6
Pre CH RL10.2

CH CH10.2 =Case study of material
handling system
Post CH SS10
Post CH HW10
Post CH LE10
Post CH QZ10
Contact Hour 11:Line Balancing


RL11.1.2 = MPC_RL_8.2
RL11.1.3 = MPC_RL_8.3
RL11.1.4 = MPC_RL_8.4
RL11.1.5 = MPC_RL_8.5
Pre CH RL11.2

CH CH11.2 =Example on precedence
charting and line balancing
Post CH SS11
Post CH HW11 Solving problems on line balance
Post CH LE11
Post CH QZ11
Contact Hour 12:Forecasting

Pre CH RL12.1 RL12.1.1 =MPC_RL_9.1 T1

RL12.1.2 = MPC_RL_9.2
RL12.1.3 = MPC_Rl_9.3
RL12.1.4 = MPC_RL_9.4
RL12.1.4 = MPC_RL_9.5
Pre CH RL12.2 RL 12.2.1 =

RL 12.2.2 =
RL 12.2.3 =
RL 12.2.4 =

CH CH12.2 =Examples on Time series
models, exponential smoothing
Post CH SS12
Post CH HW12
Post CH LE12 Using Excel for forecasting
Post CH QZ12


RL13.1.2 = MPC_RL_10.2
RL13.1.3 = MPC_RL_10.3
Pre CH RL13.2 RL 13.2.1 =

RL 13.2.2 =
RL 13.2.3 =
RL 13.2.4 =

CH CH13.2 =Example on regression
and casual relationships
Post CH SS13
Post CH HW13
Post CH LE13 Using Excel sheets for forecasting
Post CH QZ13

RL14.1.2= MPC_RL_10.4
RL14.1.3 = MPC_RL_10.5
Pre CH RL14.2

CH CH14.2 =Examples on forecast
errors
CH14.3 =Discussion on
collaborative forecasting
CH14.4 =
Post CH SS14
Post CH HW14
Post CH LE14
Post CH QZ14
Contact Hour 15: Capacity Planning and Aggregate Sales and Operations Planning

RL15.1.2 = MPC_RL_11.2
RL15.1.3 = MPC_RL_11.3
Pre CH RL15.2
During CH15 CH15.1 =Lecture/Topic Summary

CH CH15.2 =Problem using Decision
Trees
CH15.3 =Using Learning curves
Post CH SS15
Post CH HW15
Post CH LE15 Implementing a decision tree using

Excel
Post CH QZ15
Contact Hour 16: Capacity Planning and Aggregate Sales and Operations Planning

RL16.1.2 = MPC_RL_11.5
Pre CH RL16.2

CH CH16.2 =Solving Examples on
aggregate planning
Post CH SS16
Post CH HW16
Post CH LE16 Using Excel models for aggregate

planning
Post CH QZ16
Contact Hour 17: Inventory Concepts and Models


RL17.1.2 = MPC_RL_12.2
RL17.1.3 = MPC_RL_12.3
RL17.1.4 = MPC_RL_12.4
RL17.1.5 = MPC_RL_12.5
Pre CH RL17.2

CH CH17.2 =Problems based on
Inventory models
CH17.3=Usage of Pareto principle
in inventory management/analysis
Post CH SS17
Post CH HW17
Post CH LE17
Post CH QZ17
Contact Hour 18: Inventory Concepts and Models


RL18.1.2 = MPC_RL_13.2
RL18.1.3 = MPC_RL_13.3
RL18.1.4 = MPC_RL_13.4
RL18.1.5 = MPC_RL_13.5
Pre CH RL18.2
During CH18 CH18.1 =Lecture/Topic Summary

CH CH18.2 =Solving MRP calculation
Problems
Post CH SS18
Post CH HW18
Post CH LE18
Post CH QZ18
Contact Hour 19: MRP and ERP Systems


RL19.1.2 = MPC_RL_14.2
Pre CH RL19.2 RL 19.2.1 =

RL 19.2.2 =
During CH19 CH19.1 = Lecture/Topic summary

CH
CH19.2 = Problem on Capacity
Planning
CH19.3 =
Post CH SS19
Post CH HW19
Post CH LE19 Excel sheet models for Capacity

planning
Post CH QZ10
Contact Hour 20: MRP and ERP Systems

Pre CH RL20.1 RL20.1.1 = MPC_RL_14.3 T1-

RL20.1.2 = MPC_RL_14.4
RL20.1.3 = MPC_RL_14.5
Pre CH RL20.2

CH CH20.2 =Problems on Lot sizing
CH20.3= Case on MRP/ERP
implementation
Post CH SS20
Post CH HW20 Assignment related to MRP/ERP

system implementation
Post CH LE20 Developing Excel Sheet Models

for lot sizing
Post CH QZ20
Contact Hour 21: Current Approaches in Manufacturing-Lean Manufacturing

Pre CH RL21.1 RL21.1.1 = MPC_RL_15.1 T1, lecture notes

RL21.1.2 = MPC_RL_15.2
RL21.1.3 = MPC_RL_15.3
RL21.1.4 = MPC_RL_15.4
RL21.1.5 = MPC_RL_15.5
Pre CH RL21.2 RL 21.2.1 =

RL 21.2.2 =
RL 21.2.3 =
During CH21 CH21.1 = Lecture Summary

CH CH21.2 = Problem illustrations
CH21.3 = Case study
Post CH SS21
Post CH HW21
Post CH LE21
Post CH QZ21
Notes:
Contact Hour 22: Current Approaches in Manufacturing-Theory of constraints
Pre CH RL22.1 RL 22.1.1 = MPC_RL_16.1 T1

RL 22.1.2 = MPC_RL_16.2
RL 22.1.3 = MPC_RL_16.3
RL 22.1.4 = MPC_RL_16.4
RL 22.1.4 = MPC_RL_16.5
Pre CH RL22.2
During CH22 CH22.1 =Lecture Summary T1

CH CH22.2 =CaseStudy/Example in
applying Theory of Constraints
CH22.3 =Comparing Synchronous
Manufacturing (TOC) with
traditional approaches
CH22.4=Concluding remarks
Post CH SS22
Post CH HW22
Post CH LE22
Post CH QZ22
Notes:
Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
No Name Type Duration Weight Day, Date, Session, Time
EC-1 Quiz-I/ Assignment-I Online - 5% September 1-10, 2016
Quiz-II 5% October 1-10, 2016
Quiz-III/ 5% October 20-30, 2016
Assignment-II
EC-2 Mid-Semester Test Closed 2 hours 35% 25/09/2016 (AN) 2 PM TO 4 PM
Book
EC-3 Comprehensive Open 3 hours 50% 06/11/2016 (AN) 2 PM TO 5 PM
Exam Book
Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 11

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 22)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the Elearn portal. Announcements will be made on the portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound) is
permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted in all
exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available on
the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on the
dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study schedule as
given in the course handout, attend the online lectures, and take all the prescribed evaluation components
such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the evaluation scheme
provided in the handout.

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BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

Reference Book(s) & other resources

LO1 Build a strategy to develop and manufacture a product

LO3 Implement a forecasting, demand management, aggregate operations planning system

LO4 Design and implement an inventory management system.

Part B: Contact Session Plan

Academic Term FIRST SEMESTER 2016-2017

Pre CH RL1.1 RL1.1.1 = Module-1 T1

RL1.1.2 = Module 1.2 - Manufacturing Context

During CH1 CH1.1 =Introduction to course

Pre CH RL2.1 RL2.1.1 =Module-1 T1

During CH2 CH2.1 =Business strategy T1

Contact Hour 3: Functions in Manufacturing, manufacturing process planning

Pre CH RL3.1(same as RL2.1.1 =Module-1 T1

During CH3 CH3.1 =QFD

Pre CH RL4.1 RL4.1.1 = MPC_RL_3.1 T1

During CH4 CH4.1 =Lecture/topic summary T1

Contact Hour 5 Methods Analysis and Work measurement

Pre CH RL5.1 RL4.1.1 = MPC_RL_3.4 T1

During CH5 CH5.1 =Lecture/topic summary

During CH6 CH6.1 =Lecture/Topic summary

Pre CH RL7.1 RL6.1.1 = MPC_RL_4.3 T1

During CH7 CH7.1 =Lecture/Topic summary

Contact Hour 8: Plant layout and design

Pre CH RL8.1 RL8.1.1 = MPC_RL_5.1 T1

Pre CH RL8.2 RL 8.2.1 =

During CH8 CH8.1 =Lecture/topic summary

Post CH LE8 Exercise on simulation using excel

Contact Hour 9: Plant layout and material handling

Pre CH RL9.1 RL9.1.1 = MPC_RL_6.1 T1

During CH9 CH9.1 =Lecture/Topic summary

Pre CH RL10.1 RL10.1.1 = MPC_RL_7.1 Lecture notes/ppt

During CH10 CH10.1 =Lecture/Topic summary

Contact Hour 11:Line Balancing

Pre CH RL11.1 RL11.1.1 = MPC_RL_8.1 T1

During CH11 CH11.1 =Lecture/topic summary

Post CH HW11 Solving problems on line balance

Contact Hour 12:Forecasting

Pre CH RL12.1 RL12.1.1 =MPC_RL_9.1 T1

Pre CH RL12.2 RL 12.2.1 =

During CH12 CH12.1 =Lecture/topic summary

Post CH LE12 Using Excel for forecasting

Contact Hour 13:Forecasting

Pre CH RL13.1 RL13.1.1 = MPC_RL_10.1 T1

Pre CH RL13.2 RL 13.2.1 =

During CH13 CH13.1 =Lecture/topic summary

Post CH LE13 Using Excel sheets for forecasting

Pre CH RL14.1 RL14.1.1 = MPC_RL_10.3 T1

During CH14 CH14.1 =Lecture/Topic summary

Pre CH RL15.1 RL15.1.1 = MPC_RL_11.1 T1

During CH15 CH15.1 =Lecture/Topic Summary

Post CH LE15 Implementing a decision tree using

Pre CH RL16.1 RL16.1.1 = MPC_RL_11.4 T1

During CH16 CH16.1 =Lecture/Topic summary

Post CH LE16 Using Excel models for aggregate

Contact Hour 17: Inventory Concepts and Models

Pre CH RL17.1 RL17.1.1 = MPC_RL_12.1 T1

During CH17 CH17.1 =Lecture/Topic summary

Contact Hour 18: Inventory Concepts and Models

Pre CH RL18.1 RL18.1.1 = MPC_RL_13.1 T1

During CH18 CH18.1 =Lecture/Topic Summary

Contact Hour 19: MRP and ERP Systems

MP&Control-Course handout-MM ZG533

MP&Control-Course handout-MM ZG533