Oman College of Management and Technology

Transcription

1 Oman College of Management and Technology Course PIS Chapter 1 Manufacturing, Planning and Control CS/MIS Department

2 Definition Manufacturing Planning and Control system is a methodology designed to manage efficiently the flow of material, the utilization of people and equipment, and to respond to customer requirements by utilizing the capacity of our suppliers, that of our internal facilities, and in some cases that of our customers to meet customer demand. 2

3 Mfg Planning and Control System Plan the use of people Manage the efficient flow of materials Efficient use of our capacity and that of our suppliers. Possibly even our customers. Driven by customer demand and other Customer requirements Often part of the a company s ERP system. 3

4 What is the role of MPC? The MPC system tells the processes what to work on. Plans the resources that processes use (i.e. people, equipment, material). Plans for what processes will be doing in the future. 4

5 Key Areas of Influence on MPC system design Degree of Internationalization Role of the customer in the system Increasing use of Information Technology. 5

6 Performance Indicators Output results Equipment utilization Cost associated with different departments, products, labor utilization, and project conditions. Measures of customer satisfaction such as late deliveries, product returns, quantity and quality errors. 6

7 Costs and Benefits of MPC systems The costs of an MPC are substantial but so can be the rewards. Common to see ERP system costs measured at 5-10% of cost of goods sold. 7

8 Resource Planning Detailed capacity planning Sales and operations planning Master production scheduling Detailed material planning Shop-floor systems Material and capacity plans Supplier systems Demand management Front End Engine Back end Enterprise Resource Pl lanning (ERP) System 8 Manufacturing Planning and Control System

9 Resource Planning Sales and operations planning Master production scheduling Demand management Front End Detailed Detailed material Front End capacity planning Set planning of activities and systems for overall direction Material setting and (Demand capacity plans Management, Sales & Operations Planning, Resource Planning and MPS) Shop-floor systems Supplier systems Engine Back end Enterprise Resource Pl lanning (ERP) System 9 Manufacturing Planning and Control System

10 Sales and operations Engine planning Systems for detail material and capacity planning. Resource Planning Detailed capacity planning Master production scheduling Detailed material planning Shop-floor systems Material and capacity plans Supplier systems Demand management Front End Engine Back end Enterprise Resource Pl lanning (ERP) System 10 Manufacturing Planning and Control System

11 Resource Planning Sales and operations planning Master production scheduling Back Detailed End Detailed material capacity planning MPC execution systems planning Track progress Material and andcollect capacity plans data. Shop-floor systems Supplier systems Demand management Front End Engine Back end Enterprise Resource Pl lanning (ERP) System 11 Manufacturing Planning and Control System

12 Matching MPC System with the Firm needs As competitive conditions, customer expectations, supplier capabilities, and internal needs, change the MPC should change. The trend is towards on-line data access and systems. Physical changes Outsourcing mfg., etc. (Link to a website) Firms competing on delivery speed need to improve execution. 12

13 MPC Classification Schema Oil, food, drugs, watches, TV, trucks, planes, houses, ships Number of Subparts Repetitive Just-in-time MRP Project Flow Seconds Minutes Days Weeks Months 13 Time between successive units

14 MPC Classification Schema Flow (chemical plants, food, etc.) Number of Subparts MRP Just-in-time Repetitive Project Flow Seconds Minutes Days Weeks Months 14 Time between successive units

15 MPC Classification Schema Repetitive Mfg. (automobiles, high volume consumer products (i.e. TVs) Number of Subparts Repetitive Just-in-time MRP Project Flow Seconds Minutes Days Weeks Months 15 Time between successive units

16 MPC Classification Schema Number of Subparts Just-in-Time systems (shorter life cycle products e.g. fashion items). Focus on minimizing inventory in the supply chain. Repetitive Just-in-time MRP Project Flow Seconds Minutes Days Weeks Months 16 Time between successive units

17 MPC Classification Schema MRP (management of complicated products, i.e. machines, electronic equipment). Number of Subparts Repetitive Just-in-time MRP Project Flow Seconds Minutes Days Weeks Months 17 Time between successive units

18 MPC Classification Schema Project (unique; long term), buildings, one of a kind (satellites). Number of Subparts Repetitive Just-in-time MRP Project Flow Seconds Minutes Days Weeks Months 18 Time between successive units

19 Evolutionary responses to forces of Technology change Marketplace dictates Shorter product life cycles, time based competition, quality requirements Products Processes Systems Techniques Automation, production cells, simplification Company strategy Manufacturing Strategy Manufacturing processes Flexibility/responsiveness, reduced overhead costs MRP JIT MPC System 19

20 Principles The MPC should evolve to meet changing requirements in the market, technology, products, and processes. MPC systems should support the strategy and tactics pursued by the company. In SC environments, the MPC must coordinate the planning and control efforts. 20

21 Results An effective MPC can contribute to competitive performance by lowering costs and providing greater responsiveness to the market. In firms that have an integrated ERP system and database, the MPC system should integrate with and support cross-functional planning through the ERP system. 21