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FDFPLSCP4A Manage and schedule production
Presented by: XXXX – Teacher XXXX – TAFE
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Topic 1 Strategy and framework
Business relationships Relationships with internal departments Relationships with external organisations
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Supply chain
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Product life cycle phases
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Level and chase production plans
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Hybrid/combination production plan
Inventory built Inventory consumed Demand Production Schedule amount Volume Time
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Schedule relationships
Forecasts Customer orders Manufacturing equipment Bill of material Equipment capacity Planning parameters Inventory levels Manufacturing staff Production schedule Purchasing Quality control External manufacturer Warehouse Transport Customer
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Topic 2 Identify production requirements
Forecasts and customer orders Production priorities
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Seasonality
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Trend
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Topic 3 Identify resource requirements
Bill of materials and stock levels Equipment and staff resources
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Generic bill of material
Product A Sub Assembly Raw Material 1 Ingredient 1 Packaging
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Bill of material
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Material review using bill of material
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Costed bill of material
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Inventory calculation and shelf life
Item ABC1 Safety Stock 50 Order Quantity 200 Lead Time 2 days Date Receipts Issues Adjustment On Order Stock on Hand 1-Feb 100 2-Feb 50 3-Feb 200 4-Feb 250 5-Feb -20 130 Item XYZ2 Shelf Life 20 days Safety Stock 20 Lot Number Expiry Date Stock on Hand 108 15-May 16 115 20-May 40 120 25-May 80 125 27-May 20
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Inventory review
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Routing and load Capacity 100 hours Overload Routing for Item 467215
Description Mix Ingredients for 2 hours Set Up 1 Hours Run Time 2 Work Centre Line TY Capacity 100 hours Overload
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Topic 4 Develop the production schedule
Planning methods Constraints
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MRPII Hierarchy Forecasts and customer orders Business plan
Sales and operations planning Capacity Master production scheduling Material requirements planning Purchasing Manufacturing execution
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MPS Grid Item 908548 Lot Size 1000 Lead time 2 weeks 1 2 3 4 5
Lead time 2 weeks 1 2 3 4 5 Gross requirements 400 700 1100 1500 Scheduled receipts Projected available 500 300 800 Net requirements 1200 Planned order receipt 2000 Planned order release
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MRP Grid
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Enough material to meet plan?
MPS & MRP review Forecast Customer Orders Master Production Schedule Plan covers demand? No Yes Material Requirements Planning Enough material to meet plan? No Yes Review Resource Constraints
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Reorder point and Min Max System
Lot size Stock on hand Order arrives Reorder point Order arrives Lead time Order quantity Safety stock Maximum stock Order placed Stock on hand Minimum stock Lead time Order placed
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Schedule finalisation
Second Pass Schedule after MPS & MRP Review Schedule finalisation Enough capacity? Yes No Budget available? Yes No Set up issues resolved? Yes No Storage Issues resolved? Yes No Shelf Life Issues Resolved? Yes No All issues resolved? Yes Schedule Finalised
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Topic 5 Communicate the production schedule
Schedule recipients Schedule format
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MPS based schedule Item 908548 Lot Size 1000 Lead time 2 Weeks 1 2 3 4
Lead time 2 Weeks 1 2 3 4 5 Gross Requirements 400 700 1100 1500 Scheduled Receipts Projected Available 500 300 800 Net Requirements 1200 Planned Order Receipt 2000 Planned Order Release
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Shop or work order
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Schedule including capacity and load
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Daily run schedule
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Schedule by hour and shift
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Visual schedule Pr Production schedule
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Line 1 Line 2 Line 3 Cleaning Maintenance
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Topic 6 Monitor, review and adjust the production schedule
Dealing with variations Key performance indicators 33
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Key performance indicators and targets
Production review Key performance indicators and targets Daily production meeting agenda Day xx 9am To Attend: Planner Manufacturing Manager Shop Floor Supervisor Purchasing Quality Warehouse/Maintenance as necessary Previous Day’s Output Previous Day’s Supply or Resource Problems Today’s Production Issues – Supply or Resources Tomorrow’s Schedule – any issues? Future Production Issues – Supply or Resources 34
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Topic 7 Review the production schedule development process
Why review the production schedule process Continuous improvement of the schedule process
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Schedule communication
Organisation boundary Organisation Management Overall Business Plan Customers Finance Human Resources Sales Marketing Manufacturing Management Research & Development Manufacturing Staff Purchasing Planner Quality TGA Warehouse/Distribution Centres Vendors/ Suppliers Outsourced or Subcontracted Manufacturers Transport WorkCover
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Continuous improvement
Review Refine Refocus
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Final Assessments Final assessments
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