TSI Plastics Production Planning Process 9-26-11

1. TSI Plastics Production Planning Process9-26-11

2. Manufacturing Production Planning Scheduling Producing Controlling

3. Production Planning • Scheduling production • Manufacturing production • Controlling production activities

4. Scheduling Production • Before production begins the manager must know what product is being produced and how many. • This information is gained through production planning and control personnel

5. Scheduling Production – 4 Main Tasks • Routing: deciding where the work is to be done • Scheduling: deciding when the work is to be started and completed • Dispatching: issuing work orders to start actual production • Expediting: seeing that the work is progressing on schedule

6. Routing Production • Routing depends on the type of manufacturing being used. • Continuous manufacturing routes are built into the factory layout. • The product moves along fixed paths from station to station • Intermittent and custom manufacturing plants group the equipment by function.

7. Routing Production • The path of materials through the manufacturing facility are shown on a flow diagram.

8. Routing Production • A line production Traveler is used by managers to monitor total production schedules. • It includes: • A description of the operation • The product rate in pieces per hour • The number of operators and machines needed • The cost of producing the product in standard units

9. Scheduling Production • Weekly production meeting will be held to review production schedules and to expedite. • The goal is to use 100% of the manufacturing plant. • Schedules are based on: • Sales forecasts by day, week, and month for each product • Inventory levels for both raw materials and finished products • Manufacturing capacity to be schedules in terms of the number of products that can be produced per hour or day • Schedules determine the parts or products that should be manufactured each day the plant operates

10. Scheduling Production • Production schedules must also consider lead time, including the time it takes to: • Order and receive materials and parts that must be purchased • Make parts from materials • Assemble parts into products • Package products for delivery

11. Dispatching and Expediting • Dispatching involves releasing daily or weekly schedules • Expediting involves keeping the product on schedule with daily product reports • If the schedule is broken, corrective action might include: • Overtime • Retraining workers • Changing operations to improve efficiency • Holding a motivational meeting

12. Stop for Questions 1. Which of the answer choices below is not one of the main tasks of production planning? Scheduling production Manufacturing the products Controlling the product Designing the product

13. Stop for Questions 2. Which answer choice below defines routing? Seeing the that work is progressing on schedule Deciding when the work is to be started and completed Deciding where the work is to be done Issuing work orders to start actual production

14. Stop for Questions 3. Which answer choice below defines scheduling? Seeing the that work is progressing on schedule Deciding when the work is to be started and completed Deciding where the work is to be done Issuing work orders to start actual production

15. Stop for Questions 4. Which answer choice below defines dispatching? Seeing the that work is progressing on schedule Deciding when the work is to be started and completed Deciding where the work is to be done Issuing work orders to start actual production

16. Stop for Questions 5. Which answer choice below defines expediting? Seeing the that work is progressing on schedule Deciding when the work is to be started and completed Deciding where the work is to be done Issuing work orders to start actual production

17. Stop for Questions 6. What is the picture below? A quality control diagram A flow diagram A production routing chart None of the above

18. Manufacturing Production • After scheduling, the products must be produced. They run through 2 types of production: • Pilot production – Manufactures test the new production lines before placing the product in full production • Corrections for problems might include: tooling designs, production methods, plant layouts, and material handling system • Full Scale production – this is where the efficient manufacturing takes place

19. Manufacturing Production • When changes are made to the flow process, it is done on a Traveler.

20. Controlling Production Activities • There are 3 major categories of information for controlling production: • Production data – this is a report that lists the number of products schedules to be built, the number of products started, the number of products scraped, and the number of products completed. • Inspection data - comes from 3 types of inspection: material, in-work, and finished product inspection. Inspectors check materials as they move through the process • Payroll data – this is the pay to the employees for the completed work.

21. Stop for Questions 7. Ways to improve production are by correcting Product and tooling designs Production methods and plant layouts Material handling systems All of the above

22. Stop for Questions 8. Which of the following is not a major category for controlling production? Production data Product sales Inspection data Pay roll data