Production Planning and Control Chapter 7 Production Planning Professor JIANG Zhibin Department of Industrial Engineering Management Shanghai Jiao Tong University 上游充鱼大粤
Production Planning and Control Professor JIANG Zhibin Department of Industrial Engineering & Management Shanghai Jiao Tong University Chapter 7 Production Planning
国 Contents ·Introduction Master Production Scheduling (MPS) ● Material Requirement Planning (MRP) ·Capacity Planning ·Improvement in MRP 上浒充鱼大粤
Contents • Introduction • Master Production Scheduling (MPS) • Material Requirement Planning (MRP) • Capacity Planning • Improvement in MRP
Overview of Production Planning Activities Production Planning: Process Planning Given specific process planning,process Long Range Strategic capacity Planning technologies,and production conditions, Demand Forecast Aggregate Planning production planning Medi Order Master Production Scheduling Rough-cut RanL Management (MPS) capacity Planning predetermine varieties, quantities,quality,and Material Requirement Planning Capacity Req. (MRP) Planning schedules of products to Short range Operations Scheduling(Shop be produced according to floor Scheduling Control) market demand of Figure 4.1 Framework of Production Planning Activities products;
Overview of Production Planning Activities Production Planning: Given specific process planning, process technologies, and production conditions, production planning predetermine varieties, quantities, quality, and schedules of products to be produced according to market demand of products; Figure 4.1 Framework of Production Planning Activities Process Planning Aggregate Planning Master Production Scheduling (MPS) Material Requirement Planning (MRP) Operations Scheduling (Shop floor Scheduling & Control) Demand Forecast Rough-cut capacity Planning Long Range Medium Range Short range Strategic capacity Planning Capacity Req. Planning Order Management
Overview of Production Planning Activities Process Planning Time Dimensions: Long-range planning is done Long Range Strategic capacity Planning annually and focus on a planning horizon greater Demand Forecast Aggregate Planning than one year; Medium-range planning Medi Order Master Production Scheduling Rough-cut Ran Management (MPS) capacity Planning usually covers a period from 6 months to 18 months,with Material Requirement Planning Capacity Req. monthly or sometimes (MRP) Planning quarterly time increments; Short range Operations Scheduling(Shop Short-range planning covers floor Scheduling Control) a period from one day or less to six months,with Figure 4.1 Framework of Production Planning Activities weekly time increment usually. 上充道大粤
Time Dimensions: • Long-range planning is done annually and focus on a planning horizon greater than one year; • Medium-range planning usually covers a period from 6 months to 18 months, with monthly or sometimes quarterly time increments; • Short-range planning covers a period from one day or less to six months, with weekly time increment usually. Figure 4.1 Framework of Production Planning Activities Process Planning Aggregate Planning Master Production Scheduling (MPS) Material Requirement Planning (MRP) Operations Scheduling (Shop floor Scheduling & Control) Demand Forecast Rough-cut capacity Planning Long Range Medium Range Short range Strategic capacity Planning Capacity Req. Planning Order Management Overview of Production Planning Activities
Overview of Production Planning Activities Process Planning determines Process Planning the specific technologies and Long Range Strategic capacity Planning procedures required to produce a product a service. Demand Forecast Aggregate Planning Strategic capacity planning determines long-term Medi Order Master Production Scheduling Rough-cut Ran Management (MPS) capacity Planning capabilities (e.g.size and Material Requirement Planning Capacity Req. scope) (MRP) Planning Aggregate planning concerns Short range Operations Scheduling(Shop with setting up production floor Scheduling Control) rate by product family or Figure 4.1 Framework of Production Planning Activities other categories for intermediate term (6-18 months)
• Process Planning determines the specific technologies and procedures required to produce a product a service. • Strategic capacity planning determines long-term capabilities (e. g. size and scope) • Aggregate planning concerns with setting up production rate by product family or other categories for intermediate term (6-18 months). Figure 4.1 Framework of Production Planning Activities Process Planning Aggregate Planning Master Production Scheduling (MPS) Material Requirement Planning (MRP) Operations Scheduling (Shop floor Scheduling & Control) Demand Forecast Rough-cut capacity Planning Long Range Medium Range Short range Strategic capacity Planning Capacity Req. Planning Order Management Overview of Production Planning Activities
Overview of Production Planning Activities ·Master production Process Planning scheduling generates the amounts and dates of specific Long Range Strategic capacity Planning items required by orders. The inputs into MPS are Demand Forecast Aggregate Planning arrived orders and AP results. Rough-cut capacity planning Medi Order Master Production Scheduling Rough-cut Ran Management (MPS) capacity Planning is used to verify that the production and warehouse Material Requirement Planning Capacity Req. (MRP) Planning facilities,equipment,and labor are available,and the Short range Operations Scheduling(Shop key suppliers have allocated floor Scheduling Control) sufficient capacity to provide materials when needed. Figure 4.1 Framework of Production Planning Activities
• Master production scheduling generates the amounts and dates of specific items required by orders. • The inputs into MPS are arrived orders and AP results. • Rough-cut capacity planning is used to verify that the production and warehouse facilities, equipment, and labor are available , and the key suppliers have allocated sufficient capacity to provide materials when needed. Figure 4.1 Framework of Production Planning Activities Process Planning Aggregate Planning Master Production Scheduling (MPS) Material Requirement Planning (MRP) Operations Scheduling (Shop floor Scheduling & Control) Demand Forecast Rough-cut capacity Planning Long Range Medium Range Short range Strategic capacity Planning Capacity Req. Planning Order Management Overview of Production Planning Activities
Overview of Production Planning Activities Material requirement planning Process Planning takes the end product requirements from MPS and Long Range Strategic capacity Planning breaks them down into their components and subassemblies Demand Forecast Aggregate Planning to create a material plan (production orders and Medi Order Master Production Scheduling Rough-cut Ran Management (MPS) capacity Planning purchase order). ● Capacity requirement planning Material Requirement Planning Capacity Req. (MRP) Planning (CAP)allocate production resources to each production Short range Operations Scheduling(Shop order. floor Scheduling Control) Operations scheduling allocates jobs to specific Figure 4.1 Framework of Production Planning Activities machines,production lines or work centers
• Material requirement planning takes the end product requirements from MPS and breaks them down into their components and subassemblies to create a material plan (production orders and purchase order). • Capacity requirement planning (CAP) allocate production resources to each production order. • Operations scheduling allocates jobs to specific machines, production lines or work centers. Figure 4.1 Framework of Production Planning Activities Process Planning Aggregate Planning Master Production Scheduling (MPS) Material Requirement Planning (MRP) Operations Scheduling (Shop floor Scheduling & Control) Demand Forecast Rough-cut capacity Planning Long Range Medium Range Short range Strategic capacity Planning Capacity Req. Planning Order Management Overview of Production Planning Activities
Chapter 7 Production Planning Contents ·Introduction Master Production Scheduling (MPS) Material Requirement Planning (MRP) ·Capacity Planning ·Improvement in MRP 上游充道大粤
Chapter 7 Production Planning Contents • Introduction • Master Production Scheduling (MPS) • Material Requirement Planning (MRP) • Capacity Planning • Improvement in MRP
Mater Production Scheduling (1) Month 1 2 Aggregate production plan Mattress production 900 950 for mattress Week 1 2 3 4 5 6 7 8 Model 327 200 400 200 100 Model 538 100 100 150 100 Model 749 100 200 200 MPS for mattress models Aggregate production plan for mattress specifies the total number of mattress planned per month,without regard of mattress types; MPS specifies the exact types of mattress and quantities planned for production by week 上泽充鱼大粤
Mater Production Scheduling (1) Month 1 2 Mattress production 900 950 Week 1 2 3 4 5 6 7 8 Model 327 200 400 200 100 Model 538 100 100 150 100 Model 749 100 200 200 MPS for mattress models Aggregate production plan for mattress • Aggregate production plan for mattress specifies the total number of mattress planned per month, without regard of mattress types; • MPS specifies the exact types of mattress and quantities planned for production by week
Mater Production Scheduling (2) Aggregate planning specifies product groups,rather than exact items; As the next level down in the planning process,MPS is time phased plan that specifies how many and when a firm to build each end item. In the case of the furniture company Its AP may specify the total volume of mattress it plan to produce over next month,e.g.900 for the next 1 month: Its MPS identifies period by period usually weekly) which mattress styles and how many of these mattress styles are needed,200 Model 200 for Wk 1,100 Model 538 for both Wks 2 and 3 respectively,and 100 Model 749 for Wk 3. 上充鱼大粤
Mater Production Scheduling (2) Aggregate planning specifies product groups, rather than exact items; As the next level down in the planning process, MPS is time phased plan that specifies how many and when a firm to build each end item. In the case of the furniture company • Its AP may specify the total volume of mattress it plan to produce over next month, e. g. 900 for the next 1 month; • Its MPS identifies period by period ( usually weekly) which mattress styles and how many of these mattress styles are needed, 200 Model 200 for Wk 1, 100 Model 538 for both Wks 2 and 3 respectively, and 100 Model 749 for Wk 3
