Manufacturing planning control

7/23/2019 Manufacturing planning control

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5-1

Agenda (CH 5)- P 152


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5-2

Manufacturing Planning

and Control MPC 6thEdition

Chapter 5

Rememer!!!!!!


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5-3

Ma"ter Production

#cheduling

An effecti$e Ma"ter Production #chedule(MP#) pro$ide" a"i" for ma%ing good u"e of &

manufacturing re"ource"' ma%ing cu"tomer deli$er promi"e"'

re"ol$ing trade-off" eteen "ale" and'

manufacturing* and attaining the firm+" "trategic o,ecti$e"' a"

reflected in the #ale" and peration" plan.


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5-4

Ma"ter Production #cheduling

and the Manufacturing

Planning and Control #"tem

/he MP# i" a "tatement of the "pecific

product" that ma%e up manufacturing output /he MP# i" a tran"lation of the "ale" and

operation" plan into producile product" ith

their timing and 0uantitie" determined /he MP# "ho" hen product" ill e

a$ailale in the future


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5-5

MP# and the u"ine""

En$ironment (p 15)

In a make-to-stock compan' the MP# i" a

"tatement of ho much of each end item to e

produced and hen it ill e a$ailale In a make-to-order (or engineer-to-order)

firm' the MP# i" u"uall defined a" the "pecific

end item(") that ma%e up an actual cu"tomer

order

In an assemble-to-order firm' the large

numer of po""ile product comination" i"

repre"ented ith a planning ill of material"


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5-6

Attriute" of the Ma"ter

Production #chedule

/he MP# i" a "tatement of production' not of demand

/he MP# i" not a foreca"t /he MP# con"ider" factor" "uch a" capacit con"traint"'

co"t" of production' re"ource limitation"' and the "ale" and

operation" plan

/he MP# i" "tated in term" of product "pecification"3u"uallpart numer" hich ha$e "pecific ill" of material" (M)

4n a""emle-to-order en$ironment"' the MP# ma e "tated

in term" of an a$erage final product


7/595-7

MP# and 7uture utput (p 158)

#tatement of the Planned output

#pecifie" product"9 product option"

/ime of completion Ho product ill e "upplied to meet

future demand

:ifferent from foreca"t& Account"capacit planning' co"t of production'

re"ource


8/595-8

Ma"ter Production

#cheduling ;in%age"

/he MP# i" the dri$er of all detailed

manufacturing acti$itie" need to meet output

o,ecti$e" /he MP# i" the a"i" for %e inter-functional

trade-off"

Production and "ale" 7inancial udget" "hould e integrated ith

MP# acti$itie"


9/595-9

MP# in the MPC #"tem-fig

5.1 pg 155

Re"ource

planning

#ale" and operation"

planning

:emand

management

Ma"ter production"cheduling

:etailed material

planning

Ent

erpri"eRe"ourc

ePlanning(ERP

)#"tem

Front End

Engine

Rough-cut capacit

planning


10/595-10

PoerPoint pre"entation toaccompan Hei 2?? Prentice Hall' 4nc.' @pper #addleRi$er' .B. ?=55-1?

Engineering :raing" -#ho :imen"ion"'

/olerance"' etc. (not in teDt)


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5-11

A""eml :raingA""eml :raing

#ho" eDploded#ho" eDploded$ie of product$ie of product

:etail" relati$e:etail" relati$elocation" to "holocation" to "hoho to a""emleho to a""emlethe productthe product

7igure 5.11 (a)7igure 5.11 (a)


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PoerPoint pre"entation toaccompan Hei 2?? Prentice Hall' 4nc.' @pper #addleRi$er' .B. ?=55-12

Bill of MaterialP/N:1??? Name:ic(cleP/N Desc Qty Unitse!el

1??1 Handlear" 1 Each 11??2 7rameA""( 1 Each 11??8 heel" 2 Each 21?? 7rame 1 Each 2

Bill of MaterialP/N:1??? Name:ic(cleP/N Desc Qty Unitse!el1??1 Handlear" 1 Each 11??2 7rameA""( 1 Each 11??8 heel" 2 Each 21?? 7rame 1 Each 2

> 1FF5 Corel Corp.

ill of Material EDample (not in teDt)

N i ) Bill f M i lN t i ) t Bill f M t i l


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PoerPoint pre"entation toaccompan Hei 2?? Prentice Hall' 4nc.' @pper #addleRi$er' .B. ?=55-18

ill of Material for a Panel eldment Hard Roc% CafG+" Hic%or

acon Chee"eurger

umer :e"cription t

:e"cription t

"#$-%& Panel 'eldm(t 1 un

Hamurger Patt

Cheddar Chee"eacon

nion"

Hic%or #auce

urger #et

;ettuce

/omato

Red nion Pic%le

7rench 7rie"

#ea"oned #alt

11-inch Plate

HRC 7lag

1

o


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Part" grouped into familie" ith

"imilar characteri"tic"

Coding ""tem de"crie" proce""ingand ph"ical characteri"tic"

Part familie" can e produced

in dedicated manufacturing cell"

Jroup /echnologJroup /echnolog


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5-15

Jroup /echnolog #chemeJroup /echnolog #cheme

7igure 5.1?7igure 5.1?

(a) @ngrouped Part"() Jrouped Clindrical Part" (familie" of part")

Jroo$ed #lotted /hreaded :rilled Machined


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5-16

1. 4mpro$ed de"ign

2. Reduced ra material and purcha"e"

8. #implified production planning and control. 4mpro$ed laout' routing' and machine

loading

5.

Reduced tooling "etup time' or%-in-proce""' and production time

Jroup /echnolog enefit"Jroup /echnolog enefit"


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5-17

Cla""

Prepare a ill-of-material for a ham and chee"e "andich' "pecif uantit andle$el".


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PoerPoint pre"entation to

accompan Hei 2?? Prentice Hall' 4nc.' @pper #addle

Ri$er' .B. ?=55-1

Practice Prolem" (ne po""ile Kan"er)

read 2 "lice"

Ham 1 "lice

#i"" Chee"e 1 "lice

;ettuce 1926 head of lettuceMu"tard 2 tea"poon

Pic%le reli"h 1 tea"poon

Paper plate 1

Paper nap%in 1


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5-19

Ma"ter Production #cheduling

Proce"" and /echni0ue"


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5-20

:etermine "uppl and demand relation"hip"

o$er time (time-pha"ed record)- p15=

eginning alance (could e alance from

t-1' or if it i" fir"t period (on hand)L MP#-

7oreca"t

Chec% if polic i" met alance if not relea"e

order to MP#.

MP#&

#trateg to meet demand ;e$el ' cha"e'etc .

;ot "i


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5-21

PA calculation" (refer to

page 15=

First .eriod (on hand in$entor 4 t-1)' to 7tif le"" N and alance

for PA.' if no launch MP# at "pecified period and realance.

For ot/er .eriods:

eginning alance from t-1LMP#- O7oreca"t

O i" it le"" than "pecified amountQ4f e" alance a"& Leginning alance (could e alance from t-

1' or if it i" fir"t period on hand)L MP# -7Q4f no launch MP# at "pecified period and realance.


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5-22

#ummar of 7igure"

7ig 5.2- MP# relea"e "cheduled lot "i


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5-23

7ig 5.2 ("pecified MP#-Pg 15=

pat& lot "i


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5-24

/ime-Pha"ed Record (p 15=).fig 5.2 A mean" of gathering and di"plaing critical "cheduling information

(7oreca"t' a$ailale "toc%' production "chedule)-K "ee page 15=

n hand

Period

1 2 8 5

7oreca"t 5 5 1? 15

Pro,ected a$ailale alance 2? 25

O52?1?-------25

8?

O5251?-------8?

82

O8?1?-------82

82 2=

Master .rod,ction sc/ed,le 0e!el1 &$ &$ &$ &$ &$


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5-25

7ig 5.2 ("pecified MP#-Pg. 15=

pat& lot "i


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5-26

MP# Proce""3ith ;ot #i


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Ccle #toc%

ote& 4n 7igure 5.8' if e did not produce anther atch in period 8'

in$entor ould drop to to unit" and ould e elo our "afet "toc%

le$el.

e therefore "chedule a lot of 8? unit" to e produced in period 8 to

repleni"h in$entor.

Manufacturing u"ing a lot "i


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5-28

Re$i"ing the MP#-fig5.

fig 5.5 page 15F

5.

Period 2 3 6 plan (onhand)

Period

2 8 5 6

7oreca"t 2? 2? 2? 15 2?

Pro,ected

a$ailale alance

1? O2?

PA1?O2?MP#8?1?

8?

1?

1? 25

5

Ma"ter production "chedule 8? 8? 8?

;ot "i


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5-29

After 74J 5.5 Modification

ue"tion"

/he re$i"ion "hon in 7igure 5.5 "ol$e" the prolem of pro,ected negati$e a$ailale in-

$entor ut put" in clear focu" the 0ue"tion of fea"iilit.

ue"tion"&

:oe" the compan ha$e thecapacit to immediatel produce a atch that a" originall

"cheduled for period 8

Can the compan produce atche" in to con"ecuti$e period" in the future 4" material

a$ailale to meet the re0uirement" of thi" "chedule

7urthermore' high co"t" are tpicall a""ociated ith ma%ing production change".

/he ma"ter production "chedule "hould e uffered fromo$erreaction' ith change" made onlhen e""ential.


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P6-pg 1=1-Calculate PA and

MP# gi$en . ;ot "i


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PA calculation" (refer to

page 15=

First .eriod (on hand in$entor 4 t-1)' to 7tif le"" N and alance

for PA.' if no launch MP# at "pecified period and realance.

For ot/er .eriods:

eginning alance from t-1LMP#- O7oreca"t

r O i" it le"" than "pecified amount 4f prolem

"pecifie" (##)etc.Q4f e" alance a"& Leginning alance (could e alance from t-1' or if it i" fir"t period on hand)L MP# -7

Q4f no launch MP# at "pecified period and realance.


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A/P Concept

7or man product"' cu"tomer" do not eDpect immediate

deli$er' ut place order" for future deli$er.

/he deli$er date (promi"e date) i" negotiated through a

ccle of order promi"ing' the cu"tomer either a"%" henthe order can e "hipped or "peciTe" a de"ired "hipment

date.

4f the compan ha" a ac%log of order" for future

"hipment"' the order promi"ing ta"% i" to determine henthe "hipment can e made. rder promi"ing can e

coordinated ith production "chedule" u"ing a concept

%non a" a$ailale-to-promi"e (A/P).


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5-33

A$ailale-to-Promi"e

hen immediate deli$er i" not eDpected (or

i" not po""ile due to "toc%out")' a promi"ed

deli$er date mu"t e e"tali"hed /he order promi"ing ta"% i" to determine

hen the "hipment can e made

A$ailale-to-promi"e (A/P) procedure"coordinate order promi"ing ith production

"chedule"


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PA-Calculation" hen

order" oo%ed- p 1?


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P 16? ("ee neDt "lide)

5.6 & :i"crete A/P

5.= & Cumulati$e A/P


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P16?Ucalculate e$er period

in Hori


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PA-Pg 16?

:i"crete A/P& Prior alance.

7or p1& on hand

MP# -O#um (all ordersin period" till neDt MP#

7or other period"

MP#

-O#um (all ordersin period" till neDt MP#KKKKKKKnote& for other period" than fir"t calculation doe" not include Prior alance' ote a"ed on order" not

foreca"t an more


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5-38

A$ailale-to-Promi"e ;ogic3

:i"crete (p 16?)-fig 5.6

:i"crete A/P treat" each period independentl

Period

n hand 1 2 8 5

7oreca"t 5 5 1? 15

rder" 5 8 2 ? ?

Pro,ected a$ailale alance 2? 15 1? 82 22 =

A$ailale-to-promi"e 12 2

Ma"ter production "chedule 8?

;ot "i


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5-39

Cumulati$e A/P-

ote "u"e0uent i" a"ed on MP# occurrence&

2. A/P calculation" (cumulati$e logic).

7or the Tr"t period'

A/P L n-hand L MP# - #um of the order" until theneDt MP#.

7or each period hen a "u"e0uent MP# occur"'A/P Pre$iou" A/P L MP# - #um of the order until

the neDt MP#.


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P6-pg 1=1-Calculate PA and

MP# gi$en . ;ot "i


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A$ailale-to-Promi"e ;ogic3

Cumulati$e (p 16?)

5.= Cumulati$e A/P carrie" A/P unit" forard

Period

n hand 1 2 8 5

7oreca"t 5 5 1? 15

rder" 5 8 2 ? ?

Pro,ected a$ailale alance 2? 15 1? 82 22 =

A$ailale-to-promi"e 12 KMP#occur"

?

Ma"ter production "chedule 8?

;ot "i


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5-42

Cumulati$e A/P-

ote "u"e0uent i" a"ed on MP# occurrence&

2. A/P calculation" (cumulati$e logic).

7or the Tr"t period'

A/P L n hand L MP# - #um of the order" until theneDt MP#.

7or each period KKKhen a "u"e0uent MP# occur"'A/P Pre$iou" A/P(hen la"t time calculated) L

MP# - #um of the order until the neDt MP#.


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5-43

A/P3Con"uming the

7oreca"t (p 161)

4n the A/P calculation' demand i" con"idered to

e the maDimum of foreca"t and actual cu"tomer

order"/hi" i" a con"er$ati$e approach

A""ume" that e ill e$entuall "ell at lea"t the

foreca"t 0uantit

Ad,u"t" for period" here demand eDceed" the

foreca"t

P 161 i th f t d


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5-44

Page 161& con"uming thru foreca"t a"ed on

con"er$ati$e approach& ne order"

Can e accept "ee fig 5. neDt "lide 5 oder" in

period 1 deli$ered.e order" in Period 2 a"&


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5-45

ithout

doing anthing


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5-46

ote& A/P di"crete $". Cumulati$e

#ee note" page" 161S162 Another atch WP5

:i"crete A/P&


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MP# in A""emle-to-rder

En$ironment" ( P168)

4n an a""emle-to-order (A/) en$ironment' the

po""ile comination" of end item" can e huge

#pecific end item ill" of material" (M) arereplaced ith a planning ill of material"' hich

repre"ent" the potential product comination"

ne tpe of planning M i" the s,.er bill'

hich de"crie" the u"age of option" and

component" that ma%e up the a!erageproduct.


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Panning in A""emle to rder

(p168) MP# can not e a"ed on end item.&u"ed modular option comination to ma%e end item


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#uper ill of Material"

Part" u"ed in

allconfiguration"

are li"ted ith

u"age

proailit of

1.?

Mutuall eDclu"i$e

option "et" are li"tedtogether' ith a u"age

proailit for each

option

#afet("toc

%a"or"

$ariation"

inactualm

iD


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A$ailale-to-Promi"e ;ogic

ith Planning M

Common Part"

A$ailale

Jear

A$ailale

/alor

A$ailale

oo% order

/r 1 period

later

o

o

o

Xe"

Xe"

Xe"

Are the common

part" on the M

a$ailale

4" the re0ue"ted

gear option

a$ailale

4" the re0ue"ted

/alor optiona$ailale


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/o-;e$el Ma"ter

Production #chedule" hen a planning M i" u"ed' a final a""eml "chedule

(7A#) i" often u"ed

#tate" the "et of end product" to e uilt o$er a time period

/o-le$el MP# coordinate" component production and the7A#

Component production i" controlled aggregate

production plan in the 7A#

7inal a""eml i" controlled the 7A#

Either di"crete or cumulati$e A/P logic can appl


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#uper ill P 16=


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:i"crete A/P ith a /o-;e$el

Ma"ter Production #chedule

-Hor"epoer /iller" (Aggregate) Period

n hand 1 2 8 5

Production Plan 1?? 1?? 1?? 1?? 1??rder" 1?? =2 5 ? ?

Pro,ected a$ailale alance ? ? ? ? ? ?

A$ailale-to-promi"e ? 2 6 1?? 1??

Ma"ter production "chedule 1?? 1?? 1?? 1?? 1??

#afet "toc% ?

/alor rand -HP /iller" (7A#) Period

n hand 1 2 8 5

7oreca"t for model (?Y of total) ? ? ? ? ?

rder" 2 8= 28 ? ?

Pro,ected a$ailale alance 1?

A$ailale-to-promi"e 2? ?

Ma"ter production "chedule ? ? ?

;ot "i


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#uper ill& A/P Cumulati$e(p16)


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Ma"ter Production #chedule

#tailit

A "tale MP# tran"late" to "tale

component "chedule"

#tailit allo" impro$ed plant performance EDce""i$e MP# change" can lead to

reduced producti$it

7ailure to change the MP# can lead toreduced cu"tomer "er$ice and increa"ed

in$entor (failure to react)


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7ree


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Managing the Ma"ter

Production #chedule

/o e controlled' the MP# mu"t e reali"tic

People "hould onl e held accountale for

attainale performance le$el" #tailit and uffering are important

/he MP# mu"t not e o$er"tated

#um of the MP# "hould e0ual theproduction plan


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5-58

Principle"

/he MP# unit "hould reflect the u"ine""

en$ironment and the compan+" cho"en approach.

4f a common ERP dataa"e i" implemented' the

MP# function "hould u"e that data. Regardle"" of the firm+" en$ironment' effecti$e

"cheduling i" facilitated common ""tem"' time-

pha"ed proce""ing' and MP# techni0ue". Cu"tomer order proce""ing "hould e clo"el lin%ed

to MP#.


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Principle"

A/P information "hould e deri$ed from the

MP# and pro$ided to the "ale" department.

An 7A# "hould e u"ed to con$ert theanticipated uild "chedule into the final uild

"chedule.

/he ma"ter production "cheduler "hould

en"ure that the "um of the part" (the MP#) i"

e0ual to the hole (the operation" plan).

Manufacturing planning control

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