View
216
Download
3
Category
Preview:
Citation preview
3
Production Planning
Standard production planning
Forecasting
Sales & Operations Planning
Master Production Schedule
Material Requirements Planning
Purchasing / Procurement
Rough Cut Capacity PlanningInventory
Management
Customer Order Management
Finite Capacity Scheduling
Customer allocation per brewery
Production allocation per brewery
Warehousing / Shipping
(include transport management)
Distribution Requirements
Planning
Resource Requirements
Planning
Packaging Shop Floor Control
Brewing Shop Floor Control
Business plan
Capacity Requirements Planning
Definition Service Levels
Demand planning
4
Production Planning
RCCP
CRP
Forecasting
DistributionRequirements
Planning
Material Requirements
Planning
MasterProductionScheduling
5
Master Production Scheduling
Master production scheduling is the process to determine what the company plans toproduce expressed in finished products, quantities and date.
Stock objectives per master
schedule item
Sales forecast and customer orders per
master schedule item
Planned fabrication orders per master
schedule item
Action list
Work orders
Master Production Scheduling
Master data
Planning Bill of Material
Planning parameters (lead time, safety stock
etc.)
Planned inventory per
master mchedule item
6
Master Production Schedule Total Demand
Week
0 1 2 3 4 5 6 7
Requirement DC 1 4,000 4,000 4,000
Requirement DC 2 1,800 1,800 1,800
Requirement DC 3 1,200 1,200 1,200
Gross Requirement 4,000 3,000 4,000 3,000 4,000 3,000
Demand for the brewery
7
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Master Production Schedule
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
8
Master Production Schedule
Planned Available week 1: 10,00 – 4,000 = 6,000Safety stock should be 2,400, so no order
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
9
Master Production Schedule
Planned Available week 2: 6,000 – 3,000 = 3,000Safety stock should be 1,800, so no order
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
10
Master Production Schedule
Planned Available week 3: 3,000 – 4,000 = -1,000Safety stock should be 2,400 so order minimal 3,400
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Order 4,600, since order quantity = 2,300 (order release week 2)Planned available = -1,000 + 4,600 = 3,600
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
11
Master Production Schedule
Planned Available week 4: 3,600 – 3,000 = 600Safety stock should be 1,800 so order minimal 1,200
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Order 2,300, since order quantity = 2,300 (order release week 3)Planned available = 600 + 2,300 = 2,900
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
12
Master Production Schedule
Planned Available week 5: 2,900 – 4,000= -1,100Safety stock should be 2,400 so order minimal 3,500
Week
0 1 2 3 4 5 6 7
Gross requirement 4,000 3,000 4,000 3,000 4,000 3,000
Planned available 10,000 6,000 3,000 3,600 2,900 3,500 2,800 2,800
To Produce 4,600 2,300 4,600 2,300
Planned order release 4,600 2,300 4,600 2,300
Safety Stock 2,400 1,800 2,400 1,800 2,400 1,800
Order 4,600, since order quantity = 2,300 (order release week 4)Planned available = -1,100 + 4,600 = 3,500
Product: Heineken 60 cl Leadtime: 1 weekSafety stock: 3 daysOrder Quantity 2,300
13
Rough Cut Capacity Planning
RCCP is the process of converting the Master Production Schedule into requirements forkey resources. The comparison of load versus available capacity assists the planner inestablishing a feasible Master Production Schedule.
Master Production Schedule
Work Orders
Master data
Work centres
Rough Cut Capacity Planning
Summary routes
Load profile per bottleneck (key)
work centre
15
Production Planning
RCCP
CRP
Forecasting
DistributionRequirements
Planning
Material Requirements
Planning
MasterProductionScheduling
16
Material Requirements Planning
Work orders per Master Schedule
Item
MPSMaterial
Requirements Planning
Master data
Bill of Material
Planning parameters (lead time, safety stock
etc.)
Planned inventory
per component
item
Planned fabrication orders per
semi-finished item
Planned supply orders per
purchased item
Action list
Work orders
17
Capacity Requirements Planning
Master Production Schedule
Work Orders
Material Requirements
Planning
Work in process(WIP)
Master data
Work centres
Capacity Requirements
Planning
Routes
Load profile per work
centre
Recommended