...Production planning control function The main functions of PPC are the coordination of all the activities, which exist during production or manufacturing. Materials : This function is concerned with ensuring that the Raw material, standard finished parts, finished parts of products must be available while starting the operation within the time. Methods : This function is concerned with the analysis of all methods of manufacturing and selecting the best appropriate method according to the given set of circumstances and facilities. Machines and Equipments: It is important that methods of manufacturing should to be related to the available production facilities coupled with a detail study of equipment replacement policy. This function is concerned with the detailed analysis of the production facilities, maintenance procedures and equipment policy. Routing: It refers to the flow of sequence of operation and processes to be followed in producing a particular finish product. It determines manufacturing operation and their sequence. Estimating: This function is concerned with estimation of operations time. The operation time can be worked Out once the overall method and sequence of operation is fixed and process sheet for each operation is available. Loading & Scheduling: It is important that machine should be loaded according to their capabilities performance the given and according to the capacity. It is concerned with preparation of machine loads and fixation...
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...PRODUCTION PLANNING AND CONTROL Assignment A Marks 10 Answer all questions. 1. a) Explain the forecasting process? What are the techniques for monitoring forecasts? b) Explain various forecasting models. a) A planning tool that helps management in its attempts to cope with the uncertainty of the future, relying mainly on data from the past and present and analysis of trends. Forecasting starts with certain assumptions based on the management's experience, knowledge, and judgment. Qualitative & Quantitative techniques are the two techniques used for monitoring forecasts. b) There are two types of forecasting models which are : Time Series Models Causal Models or Associative Models 2. a) What is aggregate production plan? What are the pure strategies for APP? a) Aggregate production planning refers to the process of deciding the overall quantities of products to be manufactured or produced in a plant or other manufacturing facility during a medium term planning period such as a month, or a quarter. The aggregate plan output consist of the total quantities of each product or a group of product to be manufactured in the plan period of going into details of scheduling of different manufacturing activities required to achieve the planned production levels. The aggregate production will also not specify details such as the dates when material ordered against individual customer...
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...Lean Production Planning Lean production planning is a concept developed in Japan, which is based on finishing goods when they are needed (Chase, Jacobs, & Aquilano, 2006). For Riordan to implement this type of plan, an entire new strategy will need to be developed for handling inventory. Currently, each Riordan plant handles inventory independently. Now Riordan must centralize inventory and ordering systems. The two systems need to be centralized because lean production is based on the theory that goods are produced when needed, thus eliminating waste (Chase, Jacobs, & Aquiliano, 2006). Current Situation In China, the suppliers’ on-time delivery rate is only 93%. This is an unacceptable rate in a lean production planning environment. To increase this percentage, the plant will need to have deliveries more frequent so materials are always on hand. This would eliminate a potential bottleneck by having inventory on hand to mitigate a negative effect on production times. Another change to implement is in the receiving of raw materials and the shipping of their finished goods Process Improvement Part of the just in time theory of lean production is it reaches the customer “in time”. This can be accomplished by proceeding with the Shanghai move. This would reduce the steps needed to distribute products to customers. In addition to a decreased throughput time for finished goods to reach the customer, Riordan could save money, thus eliminating wasteful spending...
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...Chapter 18 Production Planning and Control In any manufacturing enterprise production is the driving force to which most other functions react. This is particularly true with inventories; they exist because of the needs of production. In this chapter the relationship of production planning and control to work-in-process inventories is stressed. Objectives of Production Planning Control The ultimate objective of production planning and control, like that of all other manufacturing controls, is to contribute to the profits of the enterprise. As with inventory management and control, this is accomplished by keeping the customers satisfied through the meeting of delivery schedules. Specific objectives of production planning and control are to establish routes and schedules for work that will ensure the optimum utilization of materials, workers, and machines and to provide the means for ensuring the operation of the plant in accordance with these plans. Production Planning and Control Functions All of the four basic phases of control of manufacture are easily identified in production planning and control. The plan for the processing of materials through the plant is established by the functions of process planning, loading, and scheduling. The function of dispatching puts the plan into effect; that is, operations are started in accordance with the plant. Actual performance is then compared to the planned performance, and, when required, corrective action is taken. In some instances...
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...Planning/Assessing Production for Toyota North America Executive Summary The Toyota Production System (TPS) is an integrated approach to work design that was developed and implemented by Toyota. The key characteristic of this system is that it takes into account the interactions that occur between technology and the human counterparts, which include employees, suppliers and customers. At its core, the TPS is a direct reflection of Toyota's management style and practices. The following summary will examine the TPS, including key terms that form the framework for the TPS, a comparison of the two most optimal locations, through the use of the weighted scoring model, for the selection of the North American plant which will be responsible for the production of the new Lexus RX330 line, an exploration of the production capacities through the use of decision trees, and provide an overall assessment of Toyota's current production strategy. I. Critical Assessment of the Toyota Production System (TPS) Today TPS Terms 1. Genchi Genbutsu- In essence means one has to observe a problem to fully understand it. One cannot simply rely on their second hand experience and second hand accounts of their experiences. For example, during hurricane Katrina, the Federal Emergency Management Agency (FEMA) initially heard second hand accounts of the damage and devastation experienced by residents of Katrina. FEMA was unable to thoroughly assess the state of emergency and issues at...
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...Problems on Aggregate Production Planning 1. Planners of a company have obtained information regarding the forecasted demand of a product as follows: Period 1 2 3 4 5 6 Total Forecast 200 200 300 400 500 200 1800 Costs Regular time: $2/unit Overtime: $3/unit Subcontract: $6/unit Inventory: $1/unit Backorder: $5/unit They now want to evaluate a plan that calls for a steady rate of regular-time output, mainly using inventory to absorb the uneven demand but allowing some backlog. Overtime and subcontracting are not used because they want steady output. They intend to start with zero inventory on hand in the first period. Prepare an aggregate plan and determine its cost using the preceding information. Assume a level output rate of 300 units per period with regular time. Note that the planned inventory is zero. There are 15 workers, each can produce 20 units per period. 2. Suppose that the regular output rate drops to 290 units per period in the above problem due to an expected change in production requirements. Costs will not change. Prepare an aggregate plan and compute its total cost for each of these alternatives: a. Use overtime at a fixed rate of 20 units per period as needed. Plan an ending inventory of zero for period 6. Backlogs cannot exceed 90 units per period. b. Use subcontracting at a maximum rate of 50 units per period; the usage need not be the same in every period. Have an ending inventory of zero in the last period. Again backlogs cannot...
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...TUGAS PERENCANAAN DAN PENGENDALIAN PRODUKSI ASSIGNMENT 2 A. Kalender Perusahaan Untuk Satu Tahun Kedepan |Januari 2013 | |21 | | | | |PRODUK A |PRODUK B |PRODUK C |PRODUK D | |1 |I |105 |113 |270 |405 | | |II |210 |225 |270 |405 | | |III |245 |263 |225 |338 | | |IV |140 |150 |135 |202.5 | |2 |I |113 |116 |279 |419 | | |II |225 |232 |279 |419 | | |III |263 |270 |233 |349 | | |IV |150 |155 |140 |209 | |3 |I |116 |124 |288 |431 | | |II |231 |249 |288 |431 | | |III |270 |290 |240 |359 | | ...
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...Introduction Global operations involves the linking and relating of four primary functions; marketing, finance and accounting, suppliers, and human resources to create a competitive advantage in global markets (Russell & Taylor, 2011). The business environment has become increasingly competitive over the past decade, due to the global economic crisis, environmental challenges, technological innovations, as well as, consumer lifestyle changes. As a result of the changes, many multi-national corporations (MNC), in an effort, to remain competitive and sustainable are responding by creating global strategic management plans to address the competitive trends occurring in the market (Kim, Bak, & Bae, 2010). In fact, the aforementioned factors created a rich environment for firms to access new technologies, materials, customer bases, as well as, the ability to form business partnerships, globally (Russell & Taylor, 2011; Nembhard, Shi, & Park, 2000). Consequently, there has been a shift in the way business operations are performed and managed. Procter and Gamble Company (P&G), is an excellent example of an iconic firm maintaining a competitive advantage in global markets through the effective implementation of global operations strategies and management. In fact, P&G is the leading consumer goods firm, generating annually $84 billion in sales, operating in 180+ countries, spanning the Americas, Europe, the Middle East and Africa (EMEA), and Asia. In...
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...Production Planning with Load Dependent Lead Times and Sustainability Aspects Institute of Information Systems Department of Business Sciences University of Hamburg In Partial Fulfillment of the Requirements for the Degree of Doktor der Wirtschaftswissenschaften (Dr. rer. pol.) Cumulative Dissertation submitted by Julia Pahl Head of board of examiners: Prof. Dr. Knut Haase First examiner: Prof. Dr. Stefan Voß Second examiner: Prof. Dr. Hartmut Stadtler Date of thesis discussion: 18. May 2012 Contents Table of Contents 1 I Framework of the Thesis 2 1 Production Planning with Load-Dependent Lead Times and Sustainability Aspects 1.1 List of Related Research Articles and Reports . . . . . . . . . . . . . . . . 1.2 Course of Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Conclusions and Research Directions . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 5 7 9 2 Cumulative Doctoral Thesis 2.1 Three Thematically Related Research Articles and Reports . . . . . . . . . 2.2 Co-Authors and Substantial Contribution of Candidate . . . . . . . . . . . 2.3 Publication of Research Articles and Reports . . . . . . . . . . . . . . . . 10 10 11 12 3 Curriculum Vitae 13 II Literature 21 1 Part I Framework of the Thesis 2 Chapter 1 Production Planning with Load-Dependent Lead Times and Sustainability...
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...By having multiple productions plants globally, it is able to create flexibility and backup options should one of their plants fail to deliver when there is natural disasters or uncertainty within the country. During the Thailand floods, its production was greatly affected as its plants were shut down and unable to operate due to the damage caused by the flood. (Thailand was responsible for the production of 891,000 forecasted vehicles, one of the biggest in SEA). Due to the crippling of its plants in Thailand, Toyota has to scale back its productions in the rest of SEA due to issues faced while exporting certain parts from Thailand. The car maker estimates the disruption in the parts supply chain has affected about 100 kinds of parts. The overall output loss caused by the floods amounted to an estimate of 37,500 vehicles. ISSUES FACED: Toyota has to be prepared for unforeseeable circumstances such as natural disasters. As shown, during the Thailand floods in 2011, its production was scaled back by 37,500 vehicles. Backup supplies from its other branches around the world creating the same vehicle parts could be supplied to SEA during this period to alleviate the burden faced by the plants in Thailand. OPINION: Safety is one of Toyota’s key concerns and also selling point. This must be ensured from the various parts that make the car, from the start to the end. It is understandable that Toyota decided to specialize each plant so that they can be focused on what they produce...
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...out over a co-worker * 10 votes to dismiss Foreman Edward George The workers are the most important asset to the company, so their interest should be first. Second, you have to figure out what to do about the votes to dismiss Ed George. Solutions: Talk to Ed George about his problems with his co-workers. Hold a meeting and get even more workers involved in the voting process, the take another vote. Item#4 Problems: * Overloading which can result in interruption of electrical power. * Not being reachable for Southern Power Solution: Contact Southern Power ASAP. See if they could come out and help with the problem. Item#5 Problem: * Balancing your work and his until Wednesday * Upping production by mid December in the long run Upping production would be the most important problem, because it’s long term. Balancing your work load is just something you have to do until your boss gets back. Solution: Schedule your...
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...UNIT 26: PLANNING AND MANAGING FOOD PRODUCTION AND BEVERAGE SERVICE Get assignment help for this unit at assignmenthelpuk@yahoo.com LO1 Understand different systems and equipment used for the volume of food production and beverage delivery in different contexts Systems: manufacturing; traditional; sous-vide; cook-chill/freeze; cook-to-order; batch; centralised; pre-prepared; individual; multi-portion; communications; technology; applications; operational/management requirements; reporting procedures Equipment: specialist; volume; equipment specifications; economics; ergonomics; integration; maintenance and ‘down time’ Contexts: types eg contract catering, events catering, conference and banqueting https://www.blogger.com/blogger.g?blogID=5649485182751853952#editor/src=sidebar LO2 Understand purchasing management for materials, commodities, beverages and equipment Supplier: contract; purchasing specification; monitoring; vendor ratings; implications for organisation Factors influencing choice: factors eg capacity, production issues, reliability, transportation and delivery, discounts, technology applications, contingency arrangements Materials, commodities and equipment: branded/non-labelled; customised; quality; availability; delivery LO3 Be able to produce and critically assess food and beverage preparation plans Plans: staffing levels and abilities; resource issues eg physical, financial; planning meeting Methodology: production schedules and methods; consistency...
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...Posh Garments Ltd.. Industrial Engineer/ Manager, IE Job Description / Responsibility A Well Reputed 100% Export Oriented Group Sr. Manager/ Manager - Planning (Bottom Division) Job Description / Responsibility * Line loading in Fast React. * Lead a team of Planners. * Target fixing based on capacity factor & efficiency or other parameters. * Monitor & plan Sewing production to meet the shipment requirement of the Company. * To follow up production target of the line wise production plan. * Make Time & Action Plan to have hard look on daily progress report & co-ordinate accordingly. * Monitoring the Daily production Reports with updated figure to know the production at a glance. * Prepare daily problem report & action plan against the problem, take proper step to solve them. * Any other task assigned by management Fakir Fashion Ltd. Sr. Manager (IPE) Job Description / Responsibility * Responsible for planning, developing and implementing allover IE & WS activities in all departments. * Setting IE team and ensuring that the targets are achieved. * Review the current policies and improve plans to improve upon the existing standards. * Setting up and maintaining controls and documentation procedures. * Prepare operation bulletin machine / line layout. * Do method / Motion / Time study in line for each style. * Capacity study of line for setting standards targets and line balancing. * Monitor the...
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...Background Sparkling Glass Limited (SGL) is a medium scale glass container manufacturing unit. For the last two years SGL has made losses because of increasing cost of production. But this year it is expected to make profits. The reasons for high cost of production have been government policies, wage agreements and sales cartels which control the inputs. This report serves as the decision support document for the selection committee appointed to find the replacement of Mr. Ashok, the General-shift-in-charge who is slated to retire in few months. Purpose Mr. Prasad, the Plant Superintendent wants to find the replacement for Mr. Ashok. Four shift-in-charges, viz. Mr. Khanna, Mr. Punjabi, Mr. Gupta and Mr. Gulati are in contention for the job. The other options available are recruitment of a new person and extension of Mr. Ashok’s tenure. The decision tree for the given case is as follows: Options Available Among the possible options, the recruitment of a new person from another company might infuse new unbiased ideas. However, the following risks outweigh the benefit of recruiting a new person: • Possibility of friction with the existing shift-in-charges: The incumbent shift-in-charges may take some time to accept the newcomer to the company and vice versa and the difference in opinions of both the parties may create some conflict. • High cost implication: SGL has suffered losses for the last two years and wants to earn profits this year. In such a situation, hiring someone...
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...the importance of aggregate planning strategies. The aggregate planning strategies has as its primary mission, set production levels in aggregated units along of a time horizon that generally ranges from 3 to 18 months, so as to achieve meet the needs identified in the long-term plan, keeping while minimum levels of costs and a good level of customer service. In aggregate planning various mathematical techniques can be used to obtain feasible schedules. With planning methods is to optimize the use of resources avoiding sudden changes in production and at the same time reduce the total cost planning. The importance of aggregate planning in the process of managing an organization is to establish plans for short and medium term to meet the requirements of the production forecast when the capacity from the standpoint of plant or equipment is relatively fixed. INTRODUCTION In this paper I’m going to talk about Aggregate Planning Strategies. The aggregate planning serves as a link between the decisions about the facilities and programming. The decision of the aggregate planning establishes production levels overall medium term, which is why it is necessary that the company these processes is implemented, making decisions and policies that relate to overtime, hiring, layoffs, outsourcing and levels inventory. Knowledge of these factors will allow us to determine production levels involved and the mix of resources used. Like the aggregate planning other types of control and programming...
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