...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 re-planning is necessary...
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...PRODUCTION PLANNING AND CONTROL FOR REDUCING MANUFACTURING THROUGHPUT TIME Amey Dhar Dubey (fy7096) Arpit Sharma (fe2365) Bhavditya Sisodiya (fw6052) College of Engineering Wayne State University Detroit, Michigan ABSTRACT This paper scans the present state of Production Planning and Control (PPC) regarding the manufacturing industry. PPC needs to undergo internal and external changes by being more dynamic and properly utilizing resources and delivery performance. In order for this to happen, the concept of crashing much be applied to better understand of how different factors affect PPC systems performance. Crashing is reduces project time by overlapping or performing two or more different steps simultaneously using additional resources (PM PrepCast). Crashing the network is the reduction of project duration by contracting and compressing the network at minimum cost. Project duration can often be reduced by appointing more labours to project activities. However, when appointing more labours, the project cost increases due to overtime and more resources being used. Time and cost requirement must be balanced to reduce project duration. The gist of this paper covers production time, along with the cost applying the concept of crashing. In addition, time management with optimum cost is vital for any project. A method to obtain optimum cost and project duration minimization is outlined. This is achieved by fully crashing the critical path or by removing non-added...
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...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 re-planning is necessary...
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...Books Sr No R-1 R-2 Other Reading Sr No OR-1 OR-2 OR-3 OR-4 OR-5 OR-6 OR-7 OR-8 OR-9 OR-10 OR-11 OR-12 Journals articles as Compulsary reading (specific articles, complete reference) The four things that a service Business must get right HBR Article , Bang & Olufsen Design Driven Innovation : HBR , Smart Product Design : HBR , Mishina, Kazuhiro. Toyota Motor Manufacturing, U.S.A., Inc. HBS Case No. 9-693-019. Harvard Business School Publishing, Boston, 1995. , Hammond, Janice H. Barilla SpA (A). HBS Case No. 9-694-046. Harvard Business School Publishing, Boston, 1994. , Latour, Almar. Nokia Handles Supply Shock with Aplomb as Ericsson of Sweden Gets Burned. The Wall Street Journal. Dow Jones & Company, Inc., 2001. , National Cranberry Cooperative HBS #688122. From Case Map , John Crane UK Ltd Case : The CAD CAM Link . HBS #691021,24p , To Move or not to Move .Case of Cathay Pacific Airways . University of Hong Kong HBS #HKU003,22p , Note on Quality: The Views of Deming, Juran, and Crosby HBS .687011 , Process Control at Polaroid , HBS, #693047 , LL Bean Item Forecasting and Inventory Management HBS, #893003, 5p , Johson Control Automotive Systems , HBS,#69308623p , Title Operations Management Concepts, Techniques & Applications Operations Management Author Evans & Collier Edition 1st Year Publisher Name Cengage Learning Tata McGraw Hill Author Norman Gaither,Greg Frazier Edition 9th Year Publisher Name Cengage Learning William Stevenson Taylor 8th Relevant Websites Sr No RW-1...
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...LESSON 8 PRODUCTION PLANNING AND CONTROL Abha Kumar STRUCTURE 8.0 8.1 8.2 8.3 8.4 Introduction Objectives Production management Product design Design of production system 8.4.1 Types of production system 8.5 Manufacturing process 8.5.1 Types of manufacturing process 8.5.2 Factors affecting the choice of manufacturing process 8.6 Production planning and control 8.6.1 Benefits to small entrepreneur 8.6.2 Steps of production planning and control 8.7 Summary 8.8 Glossary 8.9 Self-Assessment Questions 8.10 Further Readings 8.0 INTRODUCTION After taking decisions about the type of business, its location, layout etc. the entrepreneur steps into the shoe of production manager and attempts to apply managerial principles to the production function in an enterprise. Production is a process whereby raw material is converted into semi finished products and thereby adds to the value of utility of products, which can be measured as the difference between the value of inputs and value of outputs. Production function encompasses the activities of procurement, allocation and utilization of resources. The main objective of production function is to produce the goods and services demanded by the customers in the most efficient and economical way. Therefore efficient management of the production function is of utmost importance in order to achieve this objective. 114 8.1 OBJECTIVES After studying this lesson, you should be able to • • • • • • • Describe the production function and...
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...MANUFACTURING RESOURCES PLANNING What is MRP II and why it is being used Definition and History According to American Production and Inventory Control Society, MRP II can be defined as a method of the effective planning of all the resources of a manufacturing company (Higgins, Leroy and Tierney 1996). It is actually advancement or can be said as a upgrading of Material Requirement Planning System (MRP) system, which is a set of technique that uses bills of material, data and a master production schedule to calculate the requirements for materials in a manufacturing company. The MRP system was initiated in the 1960s and was spearheaded by a team of IBM innovators comprising Joe Orlicky, George Plossl and Ollie Wright who sought to create a structured methodology for planning and scheduling materials for complex manufactured products. Over the past 30 years MRP has spawned an entire industry in manufacturing and professional services. It has evolved hand in hand with technological advancements in the computer hardware industry. At the beginning, MRP systems were run on large mainframe computer costing a lot of money and required large technical staff to support them. However in the 1970s they underwent refinements that saw disparate modules get included and critical business concerns such as cost accounting and Capacity Requirements Planning get added. This gave rise to a new generation system called MRP II. Continued changes spurred by increased technological advances coupled...
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...White Paper Lean Manufacturing Lean Manufacturing Table of Contents Executive Summary.......................................................................................................................................................................................2 Introduction .......................................................................................................................................................................................................4 Lean Manufacturing—So What? .................................................................................................................................................4 Objectives .................................................................................................................................................................................................6 The Manufacturing Challenge .................................................................................................................................................................7 Globalization and Competitive Pressure ................................................................................................................................7 Mass Production to Mass Customization ...............................................................................................................................7 Shortening Product Life Cycles........................................................................
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...Manufacturing Execution System (MES) Sai Srinivas Sriperumbudur Department of Manufacturing and Mechanical Systems Integration Rochester Institute of Technology, Rochester, NY 14623, USA Sandeep Mohan Department of Manufacturing and Mechanical Systems Integration Rochester Institute of Technology, Rochester, NY 14623, USA Abstract Manufacturing Execution System (MES) came into existence with the need of managing various disciplines in an industry such as production planning, personnel and quality assurance. These various disciplines are interdependent and need to be integrated using a Manufacturing Execution System (MES). Nowadays MES is mainly being integrated with Enterprise Resource Planning (ERP) in the Computer Integrated Manufacturing System (CIMS) to reduce the complexities encountered in the production environment. This paper analyses the various functions of an MES used in the present-day industry and how it addresses the responsibilities of the shop floor of an industry. Keywords Manufacturing Execution System (MES), Enterprise Resource Planning (ERP), Computer Integrated Manufacturing System (CIMS) and Shop floor 1. Introduction Manufacturing is best defined as transformation of materials into items of greater value by means of one or more processing and/or assembly operations. A system that integrates all the operations of a manufacturing process right from processing the raw material to the completion of the final product is called a Manufacturing...
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...ERP Enterprise is the most powerful and comprehensive system available for managing the demands of complex manufacturing, distribution, and service industries. Its deep functionality gives you unparalleled control over the complexities of your global operations, with over 30 modules covering: * Global Financial Management * Customer Relationship Management * Sales and Configuration Order Management * Enterprise and Supply Chain Planning * Manufacturing Control * Sourcing and Procurement * Project Management * Quality Management * Service Management * Engineering Data Management * Dynamic Enterprise Modeling ERP Enterprise is proven across a wide range of engineering-based industries, including automotive, industrial equipment and machinery, high tech and electronics and aerospace and defense. It has more than 25 years of manufacturing know how built in and is helping run more than 5,000 companies worldwide. What it Does ERP Enterprise gives you control over every aspect of your manufacturing supply chain, from design through to delivery, and beyond to your after-market service business. The result of years of development investment and focus on core industries, ERP Enterprise delivers the deepest industry functionality available, including capabilities you simply won't find in other systems—all of which add up to more control, fewer modifications, and sharper information to make better decisions. The latest release introduces new...
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..._______________________ ------------------------------------------------- Topic: MRP II (Manufacturing Resource Planning) ------------------------------------------------- 19th October Contents Executive summary 2 Introduction and background of MRP II 3 Implement in Manufacturing Industry 6 SWOT Analysis of MRP II System 8 Conclusion 9 Recommendations (Next generation of MRP II system) 11 Reference: 13 Executive summary The purpose of this report is to illustrate what MRP II is, what features it provides, and what benefit the manufacturers could get from it as well as the existent issues in MRP II system. The research also demonstrates how MRP II was implemented in manufacturing industry by studying a case of successful implementation of MRP II software. Introduction and background of MRP II MRP II is Manufacturing Resources Planning for short. It is defined as a man machine application system for the effective planning of all resources of all manufacturing company. From the global optimal point of view, using scientific method to plan, organize, control and coordinate all the manufacturing resources and all the links of operation of enterprises effectively and reasonably is what the MRP II concerned about. The purpose of using the MRP II system is to achieve continuous and balanced production and minimize the various items in the inventory. Eventually it can...
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...Description Riordan Manufacturing Company has four locations in Albany, Georgia, Pontiac, Michigan, Hangzhou, China, and San Jose, each with unique operation needs at each location. Procedures are similar throughout the company but are executed differently. The inventory management and control is separated into three separate areas: Raw Materials Receiving; Manufacturing and Inventory; and Final Product Shipping. (Apollo Group, 2005-2008). Each of the four plants has a designated receiving area where raw materials are received. The shipments are then compared to a weekly scheduled order report as the shipments come in. When the orders are received they are entered into the inventory system. The staff is responsible for completing inventory usage reports which are entered into the inventory systems as raw materials are being used. The staff member then enters the manufactured products into the inventory systems as those items are being produced. Consumers can submit a sales order form, which is entered into the Customer Shipping and Billing System; this will then create an order shipping document. The inventory clerks can then update the inventory system based on the shipping documents. (Apollo Group, 2005-2008). This may seem to be an effective way of managing a company and its inventory but there is a large room for error and improvement. A large part of the processes is done manually between the inventory systems and the customer shipping and billing system....
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...ERP IN MANUFACTURING SECTOR Group :6 Anubhav Chaturvedi (15) Anirudh Mishra (36) Amol Singh (57) Rohit Patil (60) INTRODUCTION ERP systems have traditionally been used by capital-intensive industries such as manufacturing, Services etc. Manufacturing firms are facing new challenges and in order to stay competitive many manufacturing operations require to be regularly updated with the Information Technology solutions. The manufacturing sector is one of the main economic activities in most of the nations. The most important aspect to characterize IT adoption is the industry and its specific characteristics rather than the country the firms belong to. Different industries have different operating characteristics and environments, and the factors related to ERP use may differ accordingly. Given the complexity of manufacturing firms, we then decide which aspects of a firm influence the use of technological innovations. Most of the manufacturing companies rely on ERP software to manage the entire range of business activities from CRM, manufacturing inventory and processes, accounting software, manufacturing planning, purchasing, quality, and more. For implementing ERP in any manufacturing industry the research objectives revolve around the following parameters(Mainly cost and quality measurement) * To identify whether there is significant difference in performance measures like cost and quality in industries with well defined IT system and industries with not such well...
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...Operational Research Models and Methods in CIM1 Abstract : Many models and methods of Operational Research can be adapted for industrial applications. In this chapter, we show on one hand the main problems of a manufacturing system and, on the other hand, how they can be ranged in a hierarchical order, derived from a CIM architecture (from the strategic decisions to the production constraints). Then, we present an Operational Research tool for solving each of these problems. 1 Introduction Flexible Manufacturing Systems (FMS) are nowadays installed in the mechanical industry, especially in car factories. However, the market constraints impose to always improve the production system and the whole production organization. The concepts developed by Taylor and applied at the beginning by Ford are progressively abandoned and replaced by the Just-In-Time concept and the Computer Integrated Manufacturing philosophy (CIM). One of the aims of the CIM philosophy is to provide an integrated information system which avoids the rigid separations between the different functionalities of a complete production system. With such integrated information systems, the loss of time on one hand between the customer order and the part delivery, on the other hand between the product design and its manufacture will be drastically reduced. To understand the complete production system, it is relatively easy to find in the scientific literature excellent general books explaining the different aspects...
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...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 terms of manufacturing sites, P&G own and operate 32 US manufacturing sites located in 21 different states or territories and 102 manufacturing sites in 40 other countries (Personal Care MarketWatch, 2011; Procter & Gamble, 2014). However, global manufacturing firms are experiencing problem associated with schedule instability and demand. Consequently, these problems are resulting in...
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...Tallinn, Estonia e-mail: eduard.shevtshenko@ttu.ee ABSTRACT Paper will give the analysis of theoretical MRP base and “Monitor” and “Scala” software efficiency analysis in the solution of “resource planning management” problems. The aim is to find out what are the original features of every solution on the way to profit maximisation at manufacturing enterprise. Paper will show what are the results of software implementation at the manufacturing enterprise compared to the period of work without software. Estimation of the efficiency of the “Scala” and “Monitor” software starts from the preparation of manufacturing process stage, and stretched up to financial results achieved. In this paper results achieved throw planning activities will be compared with real results. Analyses of manufacturing problems solutions throw software installed: using of work centre loading simulation possibilities for the optimisation of present and future manufacturing capacity; pre-calculation for future products; rating of subcontractors; EOQ calculation; delivery performance analysis; optimisation of inventory; supply chain management. Theoretical MRP base analysis gives the estimation of final profit sensitivity to different input data. This work will be practically approved on the manufacturing enterprises, under the pressure of real limits of enterprise, with analyses of results achieved. The aim is to find the most optimal solution, which enables to increase profitability Estimation of existing...
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