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Prodn - Ops - PLNG & Control-2019
Prodn - Ops - PLNG & Control-2019
AND CONTROL
PLANNING PROCESS :
LONG TERM,MEDIUM
TERM AND SHORT TERM
Operations Planning and Control
Long-range planning
Greater than one year planning horizon
Intermediate-range planning
Six to nine months/ one year
Short-range planning
One day to less than six months
Levels of Operations Planning
Strategic Planning: A process of thinking through
the organization's current mission and environment
and setting forth a guide for future decisions and
results (strategic planning is done by top
management to develop long term plans).
Availability of resources.
Hierarchical Planning Process
Demand Financial
Forecasts Aggregate Constraints
Production
Plan
Size of
Workforce Units or dollars
Production Inventory subcontracted,
per month Levels backordered, or
(in units or $) lost
External/Internal to firm : Economy,Political situation,Natural/manmade calamities,unions, Multi-
skills,Vendor capacity,Raw material availability, Competitors plans…
Demand Management -Types of Demand
Make-to-Stock (MTS)
Assemble-to-Order (ATO)
Make-to-Order (MTO)
Types of Demand vs Lead Time Inventory
Investment
Low
Engineer
to Order
Make
to Order
Assemble
to Order
Make
to Stock
High
COMPONENTS
Aggregate Plan
(Product Groups)
MPS
(Specific End Items)
Guidelines for Master Scheduling
1. Work from an aggregate production plan
2. Schedule common modules when possible
3. Load facilities realistically
4. Release orders on a timely basis
5. Monitor inventory levels closely
6. Reschedule as required
Example
Executive
Line
Durable
Line
Umbrella
Compact
Line
MPS for Umbrellas
April May
Week 1 2 3 4 5 6 7
8
Executive 150 150
Durable 120
120
Compact 200 200 200 200
Inventory
Status
Order Release
MRP Processing Logic Report
(Computer-based/
Manual)
Planned
Orders Report
Order
Changes
Report
OUTPU
TS
Inputs and Outputs in Material Requirements Planning
MRP Inputs
Lot-for-lot Method
EOQ Method
Least Unit Cost Method
Steps in Calculation of MRP Net
Requirements
2)Expediting/Follow-up/Progressing
Ensuring that the work is carried out as per the
plan and delivery schedules are met.
Production Control
1. Control of Planning
2. Control of Materials
3. Control of Tooling
4. Control of Manufacturing Capacity
5. Control of Activities
6. Control of Quantity
7. Control of Material Handling
8. Control of Due Dates
9. Control of Information
Aggregate Production Planning - Example
Names Jan Feb Mar Apr May June
Beginning Inventory 200
Demand Forecast 500 600 650 800 900 800
Safety Stock(0.2 *
Demand Forecast)
Production
Requirement ( Dem
Forecast + Safety
Stock – Beg. Inv)
Ending Inventory ( Beg
Inv + Prod. Req. - Dem
Forecast)
Workers Required
Average Inventory
* Oneworker can produce 50 products per
month
Aggregate Production Planning - Solution
Names Jan Feb Mar Apr May June