1. MANUFACTURING PLANNING & CONTROL SYSTEM
Make the right goods at the right time at top quality
and do so as economically as possible.

2. Manufacturing Planning and Control (MPC)
Manufacturing Planning and Control is responsible for the planning and
control of the flow of material through the manufacturing process
The primary activities carried out are as follows:
Production planning
Implementation and Control
Inventory Management

3. A good planning system What are we going to make ?
What does it take to make it ?
What do we have ?
What do we need ?

4. PRIORITY-CAPACITY RELATIONSHIP
(Demand)
Capacity
(Resources)
Priority relates to what product are needed, how many are needed, and
when they are needed.
Capasity is the capability of manufacturing to produce goods and services.
Eventally it depends on the resources of the company : the machinery, labor,
and financial resource , and the availability of material from suppliers.

5. MPC 5 Mayor level : - Strategic business plan - Production Plan
- Master Production Schedule
- Material Requirements Plan
- Purchasing and Production Activity Control

6. STRATEGIC
BUSSINESS
PLAN
Production
Plan
Financial
Plan
Marketing
Plant
Engineering
Plan

7. Strategic business
plan
Master
Plan
Production plan
Planning
Master prod
schedule
Material req plan
Manufacturing
Planning and
Control system
implementation
Prod activity cont.
& puchasing

8. PRODUCTION PLAN
Quantity of each product group that must be produced in each period
Desired Inventory levels
Resources of equipment, labor, and material needed in each period
Availability of the resources needed

9. Master Production Schedule
Plan for the production of individual end items.
Level of detail for the MPS is higher than for the production plan

10. Material Requirements Plan
Plan for Production and Purchase of the components used in making the items in the master production schedule.
The levels of detail is high

11. Purchasing and Production Activity Control
Represent the implementation and control phase of the production planning and control system.
Purchasing is responsible for establishing and controlling the flow of raw materials into factory.
Production and Activity Control is responsible for planning and controlling the flow of work through the factory.

12. Capacity Management
At each level in the manufacturing planning and control system, the priority plan must be tested against the available resources and capacity of the manufacturing system.

13. Perencanaan Kapasitas Perencanaan Prioritas STRAG BIS RRP Manajemen
Permintaan
Perencanaan.
Produksi
RCCP
MPS
CRP
MRP
Purchasing
Ops. Seq
PAC
I/O Cont.
RRP = Resource Requirement Planning
RCCP = Rough-Cut Capacity Planning
CRT = Capacity Requirement Planning

14. Performance Measurement
MRP II System
Business Planning
Marketing Planning
Production Planning
Master Production
Scheduling
Material Requirement
Planning
Production Activity Control
Order release
Operation scheduling
Dispatching
Expediting
Production reporting
Performance Measurement
Purchasing
Vendor selection
Order placement
Vendor scheduling
Order follow-up
Demand Management
- Forecasting
- Distribution Requirement
- Order Entry
Final Assembly
Resource Planning
Rough-Cut Capacity
Capacity Requirement
Operation Management Execution
Top
Management
Operation

15. MANUFACTURING RESOURCE PLANNING ( MRP II )
MRP II provides coordination between marketing and production, marketing, finance, and production agree on a total workable plan expressed in the production plan.
Fully integrated planning and control system.

16. ENTERPRISE RESOURCE PLANNING ( ERP )
ERP is similar to the MRP II system except it dose not dwell on manufacturing. The whole enterprise is teken into account.
APICS : An accounting oriented information system for identifying and palnning the enterprise – wide resources needed to make, ship, and account for customer orders.

17. Demand Management Four mayor activities : Forecasting.
Order Processing.
Making delivery promises.
Interfacing between manufacturing planning & control and the marketplace.

18. Forecasting
Forecasting adalah sebuah prediksi mengenai apa yang akan terjadi di masa yang akan datang.
Tiga Kategori Forecasting :
Qualitative
Extrinsic
Intrinsic

19. Qualitative techniques
Projections based on judgement, intuition and informed opinions.
By their nature, they are subjective.

20. Extrinsic Techniques
Projection based on external indicators which relate to the demand for company’s products.
Example : sales of automobile tires are proportional to gasoline comsumption.

21. Intrinsic Techniques A 12-month demand history
January 92
July 84
February 83
August 81
March 66
September 75
Aprill 74
October 63
May
November 91
June
December

22. Intrinsic Techniques Based on single month :
Demand this month will be the same as last month  84
Demand this month wil be the same as demand the same month last year  92

23. Intrinsic Techniques Avarage demand :  79
Moving avarages, exp 3-month moving average,
Forecast January ( )/3 = 79
Suppose that January demand turned out to be 90 instead of 79,
Forecast February ( )/3 = 88

24. Rata-rata Bergerak Tertimbang
Misal untuk bulan Oktober (90), September (110) dan Agustus (130); diberi bobot tertimbang masing-masing 3, 2, 1 maka ramalan pada bulan Nopember adalah :
(3(90) + 2(110) + 1(130) )/ ( ) = 103.3

25. Intrinsic Techniques Exponensial Smoothing
Perioda
Bulan
Pesanan
Ramalan
α = 0.1
α = 0.3 1
Januari
120
--- 2
Februari 90
120.0 3
Maret
100
117.0
111.0 4
April 75
115.3
107.7 5
Mei
110
111.3
97.9 6
Juni 50
111.2
101.5 7
Juli
105.1
86.1 8
Agustus
130
102.1
82.8 9
September
104.9
97.0 10
Oktober
105.4
100.9 11
November --
103.9
97.6

26. Penghalusan Eksponensial
Exponensial Smoothing
Penghalusan Eksponensial
Permintaan bulan Februari D2 = 90
Ramalan bulan Februari F2 = 120
F3 = α D2 + (1-α) F2
= (0.1) (90) + (0.9) (120)
= 117
F4 = α D3 + (1-α) F3
= (0.1) (100) + (0.9) (117) = (

27. Seasional Index Seasional sales history Year Quarter 1 2 3 4 Total 122
108 81 90
401
130
100 73 96
399
132 98 71 99
400
Average
128
102 75 95

28. Seasional Index
Seasional Index = (period avg demand) / (avg demand for all periods)
SI = 128 / 100 = untuk kwartal-1
SI = 102 / 100 = untuk kwartal-2
SI = 75 / 100 = untuk kwartal-3
SI = 95 / 100 = untuk kwartal-4
The company forecast an annual demand next year of 420 units

29. Seasional Index Forecast average quarterly demand
= 420 / 4 = 105 units
Expected first-quarter demand
= 1.28 x 105 = units
Expected second-quarter demand
= 1.02 x 105 = units …

30. STRATEGI PERENCANAAN PRODUK
LEVEL METHOD
CHASE STRATEGY
HYBRID / COMPROMISE
SUBCONTRACTOR

32. CHASE

33. LEVELING PRODUCTION

34. HYBRID / COMPROMISE

35. Permintaan Produksi Inventori
PERIODA 1 2 3 4 5 6 7 8 9 10 11 12
PERMINTAAN TOTAL 15 25 35
INVENTORY 30

36. Permintaan Produksi Inventori

37. Total Cost
If the cost of carrying inventory is $5 per case per periode based on ending inventory, what is the total of carrying inventory
If the cost changing production level is $20, What is the total cost of the plan

38. PROBLEM
A Company wants to produce 10,000 units of an item over teh nest three months at a level rate. The first month has 20 working days, the second, 21 working days, and the third, 12 working days because of an annual shutdown. On the average, how much should the company produce each day to level production?

39. PROBLEM
Amalgamated Fish Sinkers makes a product group of fresh fish sinkers and wants to develop a production plan for them. The expected opening inventory is 100 cases, and they want to reduce that to 80 cases by the end of the planning period. The number of working days is the same for each period. There are no back orders. The expected demand for the fish sinkers per period is as follows: 110, 120, , 120.
a. How much should be produced each period?
b. What is the ending inventory for each period?
c. If teh cost of carrying inventory is $5 per case per period based on ending inventory, what is the total cost of carrying inventory?
d. What will be the total cost of the plan?

40. end of section