computer aided production planning and control jomy.ppt
Transcript of computer aided production planning and control jomy.ppt
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COMPUTER AIDED PRODUCTION PLANNING
& CONTROL
JAYESH SHARMAJOMY JOSEPH
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TRADITIONAL PPC SYSTEM
Forecasting
Production planning
Master scheduling
Reqmts. planning
Machine loading & scheduling
Dispatching
Production & assembly
Expediting
Purchasing
OutsideSuppliers
Inventory control
Shipping & warehousing
Quality control
Design engineering
Process planning
Estimating
Sales and marketing
CUSTOMER
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PROBLEMS WITH TRADITIONAL PPC
Plant capacity problems
Suboptimal production scheduling
Long manufacturing lead times
Inefficient inventory control
Low work centre utilization
Process planning not followed
Errors in engg. and manufacturing records
Quality problems
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Capacity planning
Forecasting
Production Planning
Master schedule
MRP
SFC
Production & assembly
Purchasing
OutsideSuppliers
Inventory management
Shipping & warehousing
Quality control
Design engineering
Process Planning
Engineering and manufacturing
database
Sales and marketing
CUSTOMER
Cost planning and control
COMPUTER INTEGRATED SYSTEM
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KEY FEATURES OF CIPMS
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Engineering and manufacturing database
Material requirements planning
Capacity planning
Inventory management
Shop floor control
Cost planning and control
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1) Engineering and manufacturing database
Comprises all the information needed to fabricate the components and assemble the products.
It includesItem master fileBill of material fileRouting fileWork center fileTool file……
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Item master file
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Bill of material file
Component item numberParent item numberQuantity per parentUnit of measurePoint of usageParent operation numberScrap allowanceCurrent engineering change number
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Routing fileRouting numberFor each operation on the routing:
Operation numberOperation descriptionWork centerMachine numberDrawing numberTool numberNC tape numberStandard setup time
Standard labor run time per pieceStandard machine run time per pieceInteroperation timeOverlap pieces or hoursNumber of machines for split operationShrinkage Alternate option number
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Work center fileWork center numberDescriptionLocationDepartment numberNumber of machinesNumber of workersWork center efficiencyWork center utilizationNumber of hours per shiftNumber of shiftsMaximum daily hoursMachine rateLabor rateOverhead rateSetup rateQueue timeWait time
For each machine in work center: Machine number Machine description Last preventive maintenance date Next preventive maintenance date
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Tool file
Tool numberDescriptionStatus (in use, available, being repaired)Number of toolsSerial numberStorage locationCurrent assignment (work center, order number)Usage codeAccumulated use since last repairEstimated tool lifeDate of last tool repair
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2) Material requirements planning (MRP)
Output ReportsOutput Reports
MRP by period report
MRP by date report
Planned order report
Purchase advice
Exception reports
Order early or late or not needed
Order quantity too small or too large
Data FilesData Files
Purchasing data
BOM
Lead times
(Item master file)
Inventory data
Masterproduction schedule
Material requirement
planning programs (computer and
software)
Masterproduction schedule
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BENEFITS OF MRP
Customer service is improved
Reduction in lead time for each time horizon.
Reduction in work-in-process
Reduction in past-due orders
Elimination of annual inventory
Increase in productivity
Capacity constraints are better understood
Inventory turn-over increases
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"Perhaps the greatest requirement of all for successful MRP installation and operation is discipline. This includes the discipline to maintain accurate stock
records, the discipline to report accurately and in good time the completion of jobs and orders and to report to the system every event that MRP should be aware
of. Many successful MRP installations have padlock on the doors to the stockrooms."
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Closed loop MRP system
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Why closed loop MRP?
The common MRP (open loop) is static in the sense that problems with production machines, quality, labor, late delivery etc. make the output of MRP more or less irrelevant.
Manual updating is difficult and time consuming and error prone also.
Closed loop MRP handle this problem of updating.
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How closed loop MRP works?
Purchase and production activities control modules interfaced with MRP-module.
Dynamic updating of order status done by purchasing interface generates updated order status from which new planned order releases.
Shop floor interface updates MRP production status by collecting daily production and operator time-sheet data.
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Manufacturing Resource planning (MRP II)
Once an MRP system is in place, inventory data can be Once an MRP system is in place, inventory data can be augmented by other useful informationaugmented by other useful information
Labor hoursLabor hours
Material costsMaterial costs
Capital costsCapital costs
Virtually any resourceVirtually any resource
Then the system is called MRP II or Manufacturing Then the system is called MRP II or Manufacturing Resource PlanningResource Planning
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An extension of the MRP system to tie in An extension of the MRP system to tie in customers and supplierscustomers and suppliers
1.1. Allows automation and integration of many Allows automation and integration of many business processesbusiness processes
2.2. Shares common data bases and business Shares common data bases and business practicespractices
3.3. Produces information in real timeProduces information in real time Coordinates business from supplier evaluation Coordinates business from supplier evaluation
to customer invoicingto customer invoicing
Enterprise resource planning
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ERP modules includeBasic MRPBasic MRPFinanceFinanceHuman resourcesHuman resourcesSupply chain management (SCM)Supply chain management (SCM)Customer relationship management (CRM)Customer relationship management (CRM)
ERP systems can be integrated withWarehouse managementWarehouse managementLogisticsLogisticsElectronic catalogsElectronic catalogsQuality managementQuality management
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3) Capacity planning
Concerned with determining the labor and equipment resources needed to meet the production schedule.
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Capacity planning for short term adjustmentsinclude decisions on
employment levelsnumber of work shiftsovertime or reduced workweekinventory stockpilingorder backlogssubcontracting
Capacity planning for long term requirements
investing in more productive or new type of machinesnew plant constructionacquisitions and buyoutsclosing down or selling off
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4) Inventory management
The inventory management module of the CIPMS should accomplish two major functions.
Inventory accounting
Inventory planning and control
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Inventory accountingInventory accounting is concerned with inventory transactions and inventory records.Inventory transactions include
receiptsissuesreturns& loans
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Inventory planning and control
Many of the planning and control activities are accomplished by the MRP module. Other functions include• Determining economic lot sizes• Determining safety stock levels• Determining reorder points• ABC inventory analysis• Analysis of usage rates for lot size calculations• Automatic generation of purchase requests
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4) Shop floor control
The functions of a shop floor control system are
Priority control and assignment of shop orders Maintain information on WIP for MRP Monitor shop order status information Provide production output data for capacity control
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Software modules in SFC system
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4) Cost planning and control
It receives data from all other CIPMS modules and reduces them to a lowest common denominator :
money
Input source InputBill of materials Components & materials usedProcess route sheets Manufacturing operations
employedTime standards Operation timesLabor & machine rates Associated costMaterial quotations Material costAccounting data Overhead rates
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Cost control
Expected cost?
Actual cost?
Why difference?
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References
1)CAD/CAM, Mikell P. Groover2)Computer based production and inventory control, Spencer B. Smith
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