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16 SCHEDULING FOR SMOOTH FLOW Objective: How to develop leveled production schedule 1. INTRODUCTION i. Three differen

16 SCHEDULING FOR SMOOTH FLOW Objective: How to develop leveled production schedule 1. INTRODUCTION i. Three different Manufacturing Environments MTS - Make to Stock - Good Forecast MTO - Make to Order ATO - Assemble to Order 2. Production Leveling i. Buffer Stocks

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16 SCHEDULING FOR SMOOTH FLOW Objective: How to develop leveled production schedule 1. INTRODUCTION i. Three differen

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  1. 16 SCHEDULING FOR SMOOTH FLOW • Objective: How to develop leveled production schedule • 1. INTRODUCTION • i. Three different Manufacturing Environments • MTS - Make to Stock - Good Forecast • MTO - Make to Order • ATO - Assemble to Order • 2. Production Leveling • i. Buffer Stocks • ii.Uniform Schedules (constant output)

  2. 3.Requirements for Leveling Production Schedule i. Continuous and stable demand ii. Short setup times - negligible setup iii Production = Demand - Ideal situation 4.Leveling focus should be on the highest volume product P - Q (Product Quantity) analysis (Pareto Chart)

  3. 5.Leveling the MPS (Master Production Schedules) i. Leveling one Product Group (Example 1/572) Wkly Production Rate winter 12,000 12,000/12 = 1,000 spring 48,000 4,000 summer 60,000 5,000 fall 42,000 3,500 ii. Leveling Multiple Products on the same line (Example 2) ABC (need to produce/month) 4,000 2,000 1,000 Three different MPS alternatives Week 1Week 2Week 3Week 4 a. 2,000A 2,000A 2,000B 1,000C b. 1,000A 500B Same for the next three weeks 250C c. 4,000A 1,000B 1,000C 1,000B

  4. 6. Level scheduling in Pull Production i Mixed-Model Production (MM) a. FAS (Final Assembly Schedule) b. MMP (Mixed Mode Production) c. Batch Size d. MMP and Production Smoothing e. The MMP Schedule Example 3/579 A 4000/20 (working days) 200 B 2000/20 100 C 1000/20 50 All 7000/20 350

  5. (AAAABBC) AB AB AC A Repeated 50 times/day 4809.6 CT = 7 x 50 = 7 minutes

  6. 7. Requirements for MMP i. Flexible workers (multi-skilled) (multi- functional) ii. Effective QA iii. Small-lot Material Supply 8. Advantages of MMP i Elimination of losses due to line changeover ii.Process Improvement - links well with QA iii.Balanced work loads AAAABBC iv. Fewer losses from material shortages

  7. 9. Production Planning and Scheduling under different circumstances i. Production Philosophy MTS MTO ATS ii. Final Assembly vs. MP Scheduling iii.MTS: Uniform-Load Production Schedule Example 4/586 iv. Assemble- to- order

  8. Example problem Data:

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