1. Production Management Systems Dr. T. Radha Ramanan Lecturer, NIT Calicut Kerala

2. Objective To develop an interactive package / courseware for production management systems for teaching-learning process To develop an interactive package / courseware for production management systems for teaching-learning process To understand the system dynamics of production planning and control systems To understand the system dynamics of production planning and control systems

3. Methodology Development of information base Development of information base Development of Aggregate production plan or production planning module Development of Aggregate production plan or production planning module Development of Material requirements planning module Development of Material requirements planning module Sequencing and scheduling module Sequencing and scheduling module

4. Development of Information base Requires complete description of product and its manufacturing process in terms of machine requirements and the flow of the product within the production system. Requires complete description of product and its manufacturing process in terms of machine requirements and the flow of the product within the production system. The bill of materials, the route sheet and the operations process chart are the main source of information base that is intended to be developed. The bill of materials, the route sheet and the operations process chart are the main source of information base that is intended to be developed.

5. Production planning module Production planning is confined to aggregates such as the total work force, output, and inventory. Production planning is confined to aggregates such as the total work force, output, and inventory. In this approach, we plan for the optimal combination of worker requirements and inventory requirements in order to meet a given demand. In this approach, we plan for the optimal combination of worker requirements and inventory requirements in order to meet a given demand. The output of this process is a description of resources utilized and an overall schedule for production called master schedule. The output of this process is a description of resources utilized and an overall schedule for production called master schedule.

6. Development of Material requirements planning module Deals with disaggregating a master schedule considering the timing of product flows within the manufacturing facility. Deals with disaggregating a master schedule considering the timing of product flows within the manufacturing facility. The MRP explosion in multi-product environment is planned to be explained with games and interactive processes. The MRP explosion in multi-product environment is planned to be explained with games and interactive processes.

7. Sequencing and scheduling module The output of the production planning processes is a description of the set of jobs to be processed by work centers during the specific period of time. The output of the production planning processes is a description of the set of jobs to be processed by work centers during the specific period of time. This is described by the methods of sequencing and scheduling jobs through machines and work centers. This is described by the methods of sequencing and scheduling jobs through machines and work centers. Animation of the loading and sequencing is planned to understand the np-hard nature of the problem. Animation of the loading and sequencing is planned to understand the np-hard nature of the problem.

8. Purchase of Equipments / Software Production planning module Sequencing and scheduling module MRP module Literature Review Development of information base Consolidation and Report preparation Time Schedule in Developing 2009 June- 2009 Dec 2010 Jan – 2010 June 2010 July – 2010 Dec 2011 Jan – 2011 June 2011 July – 2011 Dec

9. Proposed Budget Sl.No. Description Approximate cost 1. Multi media equipment 60000 2. Multimedia and animation software 320000 3. Recording and allied expenses 100000 4. Stationeries, books and consumables 50000 5. Salaries and wages (24 months @Rs.12,000 / month for 1 person) 288000 818000

10. Schemata Divide the whole work into 4 units Divide the whole work into 4 units Unit I – Introductory part Unit I – Introductory part Unit II – Aggregate production planning Unit II – Aggregate production planning Unit III – Materials Requirement Planning Unit III – Materials Requirement Planning Unit IV – Scheduling Unit IV – Scheduling

11. UNIT I - Introduction Scope of the Course Scope of the Course Introduction Introduction Classification of production systems Classification of production systems Inputs of production system Inputs of production system

12. Unit II – Aggregate Production Planning Introduction Introduction Aggregate planning Aggregate planning Master scheduling Master scheduling Variables used in aggregate planning Variables used in aggregate planning Aggregate planning strategies Aggregate planning strategies Focused strategies Focused strategies Mixed strategies Mixed strategies Interactive problems Interactive problems Master scheduling Master scheduling Disaggregation Disaggregation Format Format Interactive problems Interactive problems

13. Unit III – Materials Requirement Planning Introduction Introduction MRP and Evolution MRP and Evolution MRP terminology MRP terminology Inputs Inputs Bill of Materials Bill of Materials Illustrative examples Illustrative examples Interactive problems Interactive problems MRP logic MRP logic Illustrative examples Illustrative examples Interactive problems Interactive problems

14. Unit IV - Scheduling Introduction Introduction Flow shop scheduling Flow shop scheduling Job shop scheduling Job shop scheduling

15. References Elsayed and Elsayed, “Analysis of Manufacturing systems” Elsayed and Elsayed, “Analysis of Manufacturing systems” Richard J. Tersine, “ Production / Operations Management” Richard J. Tersine, “ Production / Operations Management” B. Mahadevan, “Operations Management” B. Mahadevan, “Operations Management” S.N. Chary, “ Operations Management” S.N. Chary, “ Operations Management”

16. Thank you Suggestions