TPPE37 Manufacturing Control

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1 TPPE37 Manufacturing Control Contents Lecure 5 Master Production Scheduling in in different Manufacturing environments Tools and techniques Distribution requirements planning Master Production Scheduling 1 Master Production Scheduling 2 The Planning Hierarchy Master Scheduling Master planning Demand management Feedback Final assembly schedule Sales and operations planning Production planning Master prod. schedule Material planning Resource planning Master (production) scheduling Rough-cut capacity plan Detailed capacity planning Front end Engine focuses on on balancing supply and demand. It It is is a statement of of manufacturing, not a statement of of market demand Cust.. order Inventory Demand forec. Equipment Distribution netw. Personell Safety stocks Plant Manuf.. Money Spare parts Time Vendor systems Shop floor systems Back end Master Production Schedule Master Production Scheduling 3 Master Production Scheduling 4

2 Overview of Master Scheduling for one-time manufacturing Demand management Customer order Forecast Project and Jobbing Sales and operations planning Production plan Resource plan Master scheduling FAS RCCP and detailed plans are established in inparallel Capacity is isconsidered when loading individual resourcesduring the the network planning. Master Production Scheduling 5 Master Production Scheduling 6 for flow manufacturing Manufacturing environment Rate based manufacturing Flow lines Kanban environments Establish a static environment Minimal rate of of change Simple capacity analysis Line Line balancing Mixed product flows Create a mix mixthat results in inlevel loading of of critical resources Customer Purchase options Construction manufacture Make to stock (MTS) Low Assembly to order (ATO) Make to order (MTO) Engineer to order (ETO) High Final assembly Delivery Master Production Scheduling 7 Master Production Scheduling 8

3 Classif. of planning environments and MTS Focus on on forecasting, service level and resource utilisation. of of finished items (FAS A B C D E F forecastbased Raw materials Master Production Scheduling 9 Master Production Scheduling 10 and MTO/ETO and ATO Focus on on delivery time and prduct option Orders are customer specific and unique of of raw materials FAS F E D C B A Raw materials Custome orderbased Focus on on delivery time, prduct option, forecasting, service level and resource utilisation. Two level FAS G H A A B C D E F Customer orderbased Forecastbased Raw materials Master Production Scheduling 11 Master Production Scheduling 12

4 -matrix Gross requirement based Based on Based on manufacturing Two-level Master Production Scheduling 13 C 2 periods B 1 2 Period C Master Production Planning () 1 period period C 1 2 Period Lowlevel Master Production Scheduling Manufacturing based Manufacturing and purchasing Buffer - Lot Sizing Demand Time Fence DTF = 0 Planning Time Fence: = 4 DTF Item Forecast Production. Forecast Actual Demand Total Demand Projected Available Balance (PAB) Available-to-Promise (ATP) Cumulative Available-to-Promise Master Production Schedule () Corresponding terms can also be befound in in MRP Released Order Firm Planned Order, FPO A planned order orderthat thatisis frozen in intime timeand quantity. An An FPO FPO status of ofan an order should no no be be set setautomatically by bythe thempc-system without interaction withe the the planner. Planned Order Master Production Scheduling 15 Master Production Scheduling 16

5 Planning horizon Time fences Planning horizon > minimial cumulative lead time Minimum = Manufacturing lead lead time time (=Cumulative lead lead time) Planning horizon is isusually longer to to allow visibility Inside the the cumulative lead lead time time are are considered as asfirm, i.e. i.e. changes can can only onlybe bemade after after thorough analysis Demand time fence (DTF) Final assembly time fence Planning time fence () Hedge time fence Cut-off time fence Capacity fence Master Production Scheduling 17 Master Production Scheduling 18 Time zones Projected Available Balance, PAB Frozen Slushy Liquid Actual from customer or invent. Customer (forecasts are ignored) No changes without thorough analysis Released (and frozen) Forecast or customer Customer consumes the forecast Reschedue-in and -out Frozen (and released) Forecast or customer Customer consumes the forecast Reschedue-in and -out Frozen (and released) Before demand time fence Period 1: PAB = On hand balance + -quantity Actual Period 2, 3,...: PAB = Previous period s PAB + -quantity Actual Between demand time fence and planning time fence 0 Demand time fence Planning time fence Planning horizon PAB = Previous period PAB + -quantity max {forecast, customer } Master Production Scheduling 19 Master Production Scheduling 20

6 Ex. Time zones, FPO Available-to-promise (ATP) 2 periods B 1 2 Period periods Demand Time Fence DTF = 4 A Buffer - Planning Time Fence: = 6 Lot Sizing: LFL DTF Period Item Forecast Production. Forecast Actual Demand Total Demand Projected Available Balance (PAB) Available-to-Promise (ATP) Cumulative Available-to-Promise Master Production Schedule () period C 1 2 Period Lowlevel Production ATP (PAB) Marketing/Sales The uncommitted portion of a company s inventory or planned production. This quantity frequently is calculated from the master production schedule and is maintained as a tool for customer order promising Master Production Scheduling 21 Master Production Scheduling 22 Available-to-promise Ex: Available-to-promise Before planning time fence Period 1 ATP = On hand balance + -quantity (if there is in period 1) Actual until next order Period 2, 3,... (where quantity exists) Where quantity exists ATP = -quantity Actual until next order After planning time fence ATP = As before (ATO) or 0 (a matter of company policy) 0001 Lamp 2 periods Buffer - Lot Sizing: FOQ=40 Demand Time Fence DTF = 3 Planning Time Fence: = 5 DTF Item Forecast Production. Forecast Actual Demand Total Demand Projected Available Balance (PAB) 10 Available-to-Promise (ATP) Cumulative Available-to-Promise Master Production Schedule () Master Production Scheduling 23 Master Production Scheduling 24

7 Two level - super bill of materials Two level (1) Family: Car Week Sales and ope. plan Customer order Net(ATP) level 0 Car Common parts Gear box Model - S261 (100%) - S262 (60%) - S263 (40%) - S264 (60%) - S265 (20%) - S266 (20%) 100% description: Common part - Planning time fence: = 6 S261 Product forecast Actual demand Project avaliable balance 0 Avaliable to promise Cumulative ATP Standard item (S261) 60% 40% description: gear box S262 - Planning time fence: = 6 Product forecast Actual demand Project avaliable balance 0 Avaliable to promise Cumulative ATP Gear box(s262) description: gear box S263 - Planning time fence: = 6 Product forecast Actual demand Project avaliable balance 0 Avaliable to promise Cumulative ATP Gear box(s263) level 1 Master Production Scheduling 25 Master Production Scheduling 26 Two level (2) Two level (3) Family: Car Week Sales and ope. plan Customer order Net(ATP) description: gear box S262 - Planning time fence: = 6 Product forecast Actual demand Project avaliable balance Avaliable to promise Cumulative ATP Family: Car Week Sales and ope. plan Customer order Net(ATP) description: gear box S262 - Planning time fence: = 6 Product forecast Actual demand Project avaliable balance 0 Avaliable to promise Cumulative ATP Master Production Scheduling 27 Master Production Scheduling 28

8 Distribution system Distribution Resource planning, DRP Make to tostock Expensive stock keeping Complex distribution network Expensive and/or time consuming setups in inmanufacturing Extensive promotion and deals Master Production Scheduling 29 Master Production Scheduling 30 The DRP matrix Interface between DRP and Distribution center A Distribution center B Direct sales Inventory location: Lot sizing: Forecast requirements In transit Net requirement Net req. consid. planned arrivals Planned arrivals Planned shipments Inventory location: Inventory location: Inventory location: Lot sizing: Lot sizing: Lot sizing: Forecast requirements Forecast requirements Forecast In transit In transit Net requirement Net requirement Net req. consid. planned arrivals Net req. consid. planned arrivals Planned arrivals Planned arrivals Planned shipments Planned shipments Demand Time Fence DTF = 0 Buffer - Planning Time Fence: = 4 Lot Sizing DTF Period Item Forecast Saf. stock Inv. on hand Production. Forecast Central wareh. Actual Demand Distrib. center A Total Demand Distrib. center B Projected Available Balance (PAB) Total Available-to-Promise (ATP) Cumulative Available-to-Promise Master Production Schedule () Central-warehouse/factory Allocation Master Production Scheduling 31 Master Production Scheduling 32

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