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March 25, 2018 | Author: Siddharth Jain | Category: Scheduling (Production Processes), Inventory, Forecasting, Production And Manufacturing, Economies


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GroupGROUP 8 068 076 084 092 100 Dipakshi Katoch Ashwani Mehta Sohini Sinha Shubham Rohatgi Renu Bargale 108 116 Swatanu Mohan Satpathy Ankit Jain 118 Akshay Kachhal Mar-12 2  The need for Production Planning  Demand Forecasting  Aggregate Production Planning  Strategies of Aggregate Planning  Scheduling  Workforce Planning  Materials Requirement Planning  Capacity Planning  Production Control using JIT  Shop-Floor Control Mar-12 3 Addresses decisions on Acquisition Utilization Allocation of limited production resources Resources include the production facilities, labor and materials. Constraints include the availability of resources, delivery times for the products and management policies. Mar-12 4 Main objective is to take appropriate decisions. Typical decisions Work force level Production lot sizes Assignment of overtime Sequencing of production runs Mar-12 5 . Process Planning Re-planning Scheduling Corrective Action Functions of PPC Loading Follow – up Dispatching Combining Functions Mar-12 6 . the less reliable the forecast will be Mar-12 7 .Objective To predict demand for planning purposes Laws of Forecasting Forecasts are always wrong Forecasts always change The further into the future. Qualitative Demand Forecasting Prediction Market Delphi Technique Game Theory Intentions and Expectations Surveys Conjoint Analysis Mar-12 8 . Quantitative Demand Forecasting Discrete Event Simulation Quantitative Analogies Neural Networks Data Mining Causal Models Segmentation Mar-12 9 . Demand changes over a period of time at a faster rate than the resources. Mar-12 10 . It is usually done for next 2 to12 months.Objective To generate a medium-term production plan To establish rough product mix To anticipates bottlenecks To align capacity and workforce plans. Aggregate planning offers strategies to absorb these fluctuations. overtime. etc. subcontracting. Identify backorder or inventory amount Determine costs of operation Continue through time horizon to calculate total cost Develop alternate plans and compute cost for each Select the plan that meets objectives Mar-12 11 .Guidelines for Aggregate Planning Determine demand for each period Consider company policies that may have impact Determine capacities for each period Regular time. Cost is a linear function composed of unit cost and number of units.Assumptions in Aggregate Planning The regular output capacity is the same in all periods. Mar-12 Contd… 12 . Plans are feasible : sufficient inventory capacity exists to accommodate a plan. and changes in output can be made as needed. subcontractors with appropriate quality and capacity are standing by. Assumptions in Aggregate Planning All costs associated with a decision option can be represented by a lump sum or by unit cost that are independent of the quantity involved Cost figures can be reasonably estimated and are constant for the planning horizon Inventories are built up and drawn down at a uniform rate and output occurs at a uniform rate throughout each period Mar-12 13 . Output of Aggregate Planning Production quantity from regular time. overtime and subcontracted time Inventory held for determination of how much warehouse space and working capital is needed Backlog or stock-out quantity for determining the customer service levels Mar-12 14 . Level plans Use a constant workforce & produce similar quantities each time period Use inventories and backorders to absorb demand peaks & valleys Chase plans Minimize finished good inventories by trying to keep pace with demand fluctuations Mar-12 15 . Level plans Production Demand Units Time Mar-12 16 . Chase plans Production Demand Series1 Series1 Units Time Mar-12 17 . Hybrid or Mixed Strategies Build-up inventory ahead of rising demand and use backorders to level extreme peaks Layoff or furlough workers during lulls Subcontract production or hire temporary workers to cover short-term peaks Reassign workers to preventive maintenance during lulls Influencing Demand Mar-12 18 . Concerned with timetable of production Scheduling arranges the different manufacturing operations in order of priority. fixing the time & date for the commencement & completion of each operation. Types of scheduling Forward scheduling Backward scheduling Mar-12 19 . The pattern of scheduling differs from one job to another which is explained as below. Master Schedule Production Schedule Manufacturing Schedule Scheduling of Job Order Manufacturing Mar-12 20 . To find out and direct Right people Right place Right time Right price Mar-12 21 . Issues Basic Staffing Calculations and labor hours Working Environment Flexibility/Agility Quality Mar-12 22 . MRP is a production planning and inventory control system used to manage manufacturing processes. An MRP system has 3 major objectives Ensure materials are available for production and products are available for delivery to customers Maintain the lowest possible level of inventory Plan manufacturing activities. delivery schedules and purchasing activities Mar-12 23 . Mar-12 24 .MRP steps Takes output from the planning phase (master plan) Combines that with the information from the inventory record and product structure records Determines a schedule of timing and quantities for each item The basic idea is to get the right materials to the right place at the right time. Mar-12 25 . Mar-12 26 . The process of determining the production capacity needed to meet changing demands Maximum amount of work that an organization is capable of completing in a given period of time Mar-12 27 . Wrong Capacity Mar-12 28 . Classes of capacity planning Lead strategy Lag strategy Match strategy Mar-12 29 . Issues Stand-alone capacities and congestion effects Capacity Strategy Make-or-Buy Flexibility Scalability and learning curves Mar-12 30 . Objectives To eliminate waste To improve quality To minimize lead time To reduce costs To improve productivity Mar-12 31 .JIT is the technique for reducing inventories and elimination of waste in the production system. Examples McDonalds' Office Xerox Paper Mar-12 32 .Pull production and kanban JIT is associated with pull systems. Toyota was the first developer of kanban system. Issues JIT Interdependencies Implementing Issues JIT purchasing Expected Outcomes Mar-12 33 . .Objective To control flow of work through plant and coordinate with other activities (e. quality control. preventive maintenance. etc.) Mar-12 34 .g. Material Flow Control Mar-12 35 . Functions Gross Capacity Control Match line to demand by staffing (workers/shifts) Varying length of work week (or work day) Using outside vendors to augment capacity Mar-12 Contd… 36 . Functions Bottleneck Planning Handling of bottlenecks Cost of capacity is the key Stable bottlenecks are easier to manage Span of Control Physically or logically decompose system Span of labor and process management Mar-12 37 . Issues Customization SFC is often the most highly customized activity in a plant. Information Collection SFC represents the interface with the actual production processes and is therefore a good place to collect data. Contd… Mar-12 38 . Issues Simplicity Departures from simple mechanisms must be carefully justified. Mar-12 39 . THANK YOU . Management Science II. Abha Kumar Production and Inventory Control. Gaafar. Lotfi K. Lesson 8. by Wallace J Hopp and Mark J Spearman.T. Graves. by Dr. Narendran.T. Nov1999 (pdf format) Mar-12 41 . by Stephen C.com Production Planning and Control. 2005 (ppt format) Manufacturing Planning and Control. IIT Madras (pdf format) Shop floor Control. 1996-2000 www. MIT Boston.factory-physics. by Dr. net/birubiru/aggregateplanning-2069281 http://www. Billington Mar-12 42 .org/wiki/Aggregate_planning http://www.edu/murphys/2009%20SLIDE %20PACKET/Chapter13AggPlanFINAL.wikipedia. Mcleavey and Peter J.pdf http://www.buec.com/doc/11590350/AggregatePlanning Production Planning and Inventory Control. Dennis W. by Seetharama L. 2nd Edition.http://en.udel.slideshare.scribd. Narasimhan.
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