21. Manufacturing Planning Control

[MUSIC] Welcome back to our lesson on Manufacturing Planning and Control.
Upon completion at this lesson learners should be able to describe the key types of production plans and discuss the hierarchy of planning and control processes and systems.
Let’s take a look at three production plan types, Level Production, Chase Production, and Mixed Strategy.
Level Production is when operation strives to produce a relatively constant amount of product to each period. To address peak period demand, inventory is slowly built up. To serve as stock for peak sales. The automotive industry prefers this model, as it supports a constant flow of materials, equipment utilization, and stable use of the workforce. Chase Production Plans strive to maintain a stable inventory level while varying production output to chase demand.
Candy manufacturing is an example of where Chase Production may be used. Given the quality impact of holding excess inventory for a long time, stale candy, a relatively low and consistent level of inventory may be desired. With production ramping up to meet demand in a short time window to address demand requirements for holidays, such as Halloween.
Finally, a mixed strategy strives to strike a balance between the two allowing some built-up of inventory at times during the year while also varying production quantity.
No paper, no book paper, a manufacturing maybe an example of this, with a high demand in the back to school season and a product that is relatively stable, a stored inventory. Companies can build up inventory anticipation of back to school sales and then further ramp up production In the final weeks before the sales.
Until this point, our discussion has been on forecasting demand, aligning sales and operations and business plans, and high-level production planning concepts. It is important to note that there are a number of other steps that are required to drive operations. From a sales forecast to detailed machine level scheduling. This diagram represents a generally accepted model of the various components of detailed production planning and control.
A key element of planning and control is ensuring that materials, labor, and equipment capacity all come together in a specific time phased sequence. Accordingly, the steps on this chart depict moving from high leve demand and capacity planning, where forecasts are aligned with specific production facilities or distribution centers.
To aggregate production planning for coming months to master production scheduling and final assembly schedules, which then drive the procurement of specific materials required to meet production requirements. And finally, development of specific hourly short ranged schedules, aligning specific production runs to specific production equipment.
All of these levels of planning must be balanced and synchronized and they must reflect reality, not a perfect world assumption and machines do break. Production quality isn’t always perfect and requires rework. Suppliers aren’t always perfect in their delivery and production. All of these new onsets need to be considered, in developing effective production plans.
In this lesson we have described the key types of production plans and discuss the hierarchy of Planning and Control Processes and Systems. Thank you for joining us and we’ll see you on the next lesson. [SOUND]

Jim Rohn Sứ mệnh khởi nghiệp