Manufacturing Production Planning

1. Manufacturing Production Planning Scheduling Producing Controlling

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

3. 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

4. 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

5. 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.

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

7. Routing Production • A line production routing sheet 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

8. Scheduling Production • The line production routing sheet is used to help schedule. • 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

9. Scheduling Production • Production schedules most 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

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

17. 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: product designs, tooling designs, production methods, plant layouts, and material handling system • Full Scale production – this is where the efficient manufacturing takes place

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

19. 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.

20. 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

21. 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