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Production Manager 1

Production Manager 1. Strategic Planning Forecasting Aggregate Plan (AP) Master Production Schedule (MPS) Material Req. Planning (MRP, JIT) Capacity Req. Planning (CRP, TOC) Scheduling, Sequencing of jobs/lots Process Control (SPC) Distribution of Goods. Production Manager 2.

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Production Manager 1

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  1. Production Manager 1 • Strategic Planning • Forecasting • Aggregate Plan (AP) • Master Production Schedule (MPS) • Material Req. Planning (MRP, JIT) • Capacity Req. Planning (CRP, TOC) • Scheduling, Sequencing of jobs/lots • Process Control (SPC) • Distribution of Goods

  2. Production Manager 2 • Product Development • Product Mix • Raw Material Blending • Facility Location • Capacity Planning • Project Management • Quality Management • Maintenance • Human Resource Management

  3. Capacity Planning • Process Selection • Investment, Econ. Of Scale • Break-Even Analysis • Market Forecast, Risk Assessment • Decision Trees • Layout, SLP method

  4. Transport, location • Markets, raw material, labour, ... • Transport Models • Facility Location Models • Other considerations • Multi Criteria Decisions • Even > 1 decision maker • AHP-method

  5. Product Mix • Resources known • Determine Product Composition • Max Profit Contribution • LP: Linear (NLP), Continous (IP), Deterministic (SP), Static (DP) • Sensitivity Analysis • Shadow Prices • See ProductMix.xls in chapter 3, page 98- in W&A

  6. Raw Material Handling • Raw Material Blending (Diet) • Grading Raw Material • Cutting Stock • Packing, Loading • Optimization Models (LP, IP) • See Blending.xls chapter 4, page 160 in W&A • Also CuttingStock.xls in chapter 6 page 327

  7. Production Plans (AP) • Seasonal peaks • Aggregate Unit • Production, inventory, work force • Overtime, shifts • Subcontract, Backlog, Shortage • Spreadsheet • LP, Transportation Method • Basis for Cash Flow Planning • See ProductionScheduling.xls in chapter 3, page 108- in W&A and also AP pages 150-160

  8. MPS, Production Schedule • AP provides the framework • 4 – 6 weeks • Max (Orders, Forecast) • Frozen Time Zone • Batch Sizes • IP

  9. Mat. Req. Plan (MRP, JIT) • Reduces Inventories • Requires: • Inventory Computer System • Bill of Materials (BOM) • “Frozen” Production Schedules • Discipline • Lot Sizing (IP, DP)

  10. Inventory Control • Based on Forecasting • Minimizing Total Cost • Order Quantities/Lot Sizes (Q) • Reorder Point (R) • Optimization

  11. Cap. Req. Plan (CRP, TOC) • Balancing Capacity & Flow • Based on Process Analysis • Find the Bottleneck (TOC) • Simulation

  12. Short Term Job Scheduling • Determine sequence (batches, orders) • Processing times, Due dates • SPT, EDD, LPT, … • Criteria (flow, tardiness, …) • Other related problems: • Min Setup Times (TSP) • Shift Scheduling • Heuristics (GA, SA, TS)

  13. Distribution • Min Cost, Max Service • Vehicle Routing • Capacity, Time windows • Clark & Wright Savings Method • Network Models, LP, IP • Collection (milk, garbage, …)

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