FDFPLSCP4A Manage and schedule production Presented by: XXXX – Teacher XXXX – TAFE

Topic 1 Strategy and framework Business relationships Relationships with internal departments Relationships with external organisations

Supply chain

Product life cycle phases

Level and chase production plans

Hybrid/combination production plan Inventory built Inventory consumed Demand Production Schedule amount Volume Time

Schedule relationships Forecasts Customer orders Manufacturing equipment Bill of material Equipment capacity Planning parameters Inventory levels Manufacturing staff Production schedule Purchasing Quality control External manufacturer Warehouse Transport Customer

Topic 2 Identify production requirements Forecasts and customer orders Production priorities

Seasonality

Trend

Topic 3 Identify resource requirements Bill of materials and stock levels Equipment and staff resources

Generic bill of material Product A Sub Assembly Raw Material 1 Ingredient 1 Packaging

Bill of material

Material review using bill of material

Costed bill of material

Inventory calculation and shelf life Item ABC1   Safety Stock 50 Order Quantity 200 Lead Time 2 days Date Receipts Issues Adjustment On Order Stock on Hand 1-Feb 100 2-Feb 50 3-Feb 200 4-Feb 250 5-Feb -20 130 Item XYZ2   Shelf Life 20 days Safety Stock 20 Lot Number Expiry Date Stock on Hand 108 15-May 16 115 20-May 40 120 25-May 80 125 27-May 20

Inventory review

Routing and load Capacity 100 hours Overload Routing for Item 467215   Description Mix Ingredients for 2 hours Set Up 1 Hours Run Time 2 Work Centre Line TY Capacity 100 hours Overload

Topic 4 Develop the production schedule Planning methods Constraints

MRPII Hierarchy Forecasts and customer orders Business plan Sales and operations planning Capacity Master production scheduling Material requirements planning Purchasing Manufacturing execution

MPS Grid Item 908548 Lot Size 1000 Lead time 2 weeks 1 2 3 4 5   Lead time 2 weeks 1 2 3 4 5 Gross requirements 400 700 1100 1500 Scheduled receipts Projected available 500 300 800 Net requirements 1200 Planned order receipt 2000 Planned order release

MRP Grid

Enough material to meet plan? MPS & MRP review Forecast Customer Orders Master Production Schedule Plan covers demand? No Yes Material Requirements Planning Enough material to meet plan? No Yes Review Resource Constraints

Reorder point and Min Max System Lot size Stock on hand Order arrives Reorder point Order arrives Lead time Order quantity Safety stock Maximum stock Order placed Stock on hand Minimum stock Lead time Order placed

Schedule finalisation Second Pass Schedule after MPS & MRP Review Schedule finalisation Enough capacity? Yes No Budget available? Yes No Set up issues resolved? Yes No Storage Issues resolved? Yes No Shelf Life Issues Resolved? Yes No All issues resolved? Yes Schedule Finalised

Topic 5 Communicate the production schedule Schedule recipients Schedule format

MPS based schedule Item 908548 Lot Size 1000 Lead time 2 Weeks 1 2 3 4   Lead time 2 Weeks 1 2 3 4 5 Gross Requirements 400 700 1100 1500 Scheduled Receipts Projected Available 500 300 800 Net Requirements 1200 Planned Order Receipt 2000 Planned Order Release

Shop or work order

Schedule including capacity and load

Daily run schedule

Schedule by hour and shift

Visual schedule Pr Production schedule Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Line 1 Line 2 Line 3 Cleaning Maintenance

Topic 6 Monitor, review and adjust the production schedule Dealing with variations Key performance indicators 33

Key performance indicators and targets Production review Key performance indicators and targets Daily production meeting agenda Day xx 9am To Attend: Planner Manufacturing Manager Shop Floor Supervisor Purchasing Quality Warehouse/Maintenance as necessary Previous Day’s Output Previous Day’s Supply or Resource Problems Today’s Production Issues – Supply or Resources Tomorrow’s Schedule – any issues? Future Production Issues – Supply or Resources 34

Topic 7 Review the production schedule development process Why review the production schedule process Continuous improvement of the schedule process

Schedule communication Organisation boundary Organisation Management Overall Business Plan Customers Finance Human Resources Sales Marketing Manufacturing Management Research & Development Manufacturing Staff Purchasing Planner Quality TGA Warehouse/Distribution Centres Vendors/ Suppliers Outsourced or Subcontracted Manufacturers Transport WorkCover

Continuous improvement Review Refine Refocus

Final Assessments Final assessments