production planning and inventory control
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PRODUCTION PLANNING AND PRODUCTION PLANNING AND CONTROLCONTROL
PPCPPC
PRODUCTION PLANNING AND PRODUCTION PLANNING AND CONTROL OPTIMISES THE PROCESS CONTROL OPTIMISES THE PROCESS OF CONVERSION OF INPUT OF CONVERSION OF INPUT (MATERIALS,MACHINES,LABOUR) (MATERIALS,MACHINES,LABOUR) INTO OUTPUT (FINISHED GOODS)INTO OUTPUT (FINISHED GOODS)
PPCPPC
INPUTTRANSFORMATION
PROCESSOUTPUT
PPCPPC
PPC ACTIVITIES INCLUDEPPC ACTIVITIES INCLUDE• SELECTING PROCESSESSELECTING PROCESSES• ARRANGING LAYOUTSARRANGING LAYOUTS• SELECTING AND LOCATING FACILITIESSELECTING AND LOCATING FACILITIES• MEASURING PERFORMANCEMEASURING PERFORMANCE• SCHEDULINGSCHEDULING• MANAGING INVENTORYMANAGING INVENTORY• PLANNING PRODUCTIONPLANNING PRODUCTION
BATCH PRODUCTIONBATCH PRODUCTION
PROCESS MANY PROCESS MANY DIFFERENT JOBS AT THE DIFFERENT JOBS AT THE SAME TIME IN BATCHESSAME TIME IN BATCHES
MASS PRODUCTIONMASS PRODUCTION
PRODUCES LARGE PRODUCES LARGE VOLUMES OF STANDARD VOLUMES OF STANDARD PRODUCT FOR A MASS PRODUCT FOR A MASS
MARKETMARKET
CONTINUOUS CONTINUOUS PRODUCTIONPRODUCTION
PRODUCES VERY HIGH PRODUCES VERY HIGH VOLUME COMMODITY VOLUME COMMODITY
PRODUCTS PRODUCTS
PROJECTPROJECT
ONE AT A TIME ONE AT A TIME PRODUCTION OF A PRODUCTION OF A
PRODUCT TO CUSTOMER PRODUCT TO CUSTOMER ORDERORDER
PRODUCT PROCESS MATRIXPRODUCT PROCESS MATRIX
PROJECT
BATCH PRODUCTION
MASS PRODUCTION
CONTINUOUSPRODUCTION
STANDARDISATION
VOLUME
PPCPPC
PRODUCTION ENGINEERS DEAL WITH PRODUCTION ENGINEERS DEAL WITH PEOPLE, TECHNOLOGY, AND PEOPLE, TECHNOLOGY, AND DEADLINES.DEADLINES.
THESE PEOPLE NEED GOOD THESE PEOPLE NEED GOOD TECHNICAL,CONCEPTUAL, AND TECHNICAL,CONCEPTUAL, AND BEHAVIOURIAL SKILLS.BEHAVIOURIAL SKILLS.
THEIR ACTIVITIES ARE CLOSELY THEIR ACTIVITIES ARE CLOSELY INTERCONNECTED WITH OTHER INTERCONNECTED WITH OTHER FUNCTIONAL AREAS OF A FIRMFUNCTIONAL AREAS OF A FIRM
PPCPPC
PPC FUNCTION IS AKIN TO PPC FUNCTION IS AKIN TO THE FUNCTION OF THE THE FUNCTION OF THE
BRAIN IN A HUMAN BODYBRAIN IN A HUMAN BODY
PPCPPC
PRODUCTION PLANNING AND PRODUCTION PLANNING AND CONTROL HAS TWO IMPORTANT CONTROL HAS TWO IMPORTANT FUNCTIONS.FUNCTIONS.
PPCPRODUCTION PLANNING AND
CONTROL
PLANNING (METHODS)
CONTROLLING (PROGRAMMING)
PPCPPC
PLANNING SECTION MAIN FUNCTIONS ARE:PLANNING SECTION MAIN FUNCTIONS ARE:
MAKE OR BUY DECISIONMAKE OR BUY DECISIONSELECTING PROCESSSELECTING PROCESSFACILITY PLANNINGFACILITY PLANNINGPLANT LAYOUTPLANT LAYOUTMETHODISINGMETHODISINGJIGS AND FIXTURES REQUIREMENT PLANNINGJIGS AND FIXTURES REQUIREMENT PLANNINGSTANDARD TOOLSSTANDARD TOOLSMATERIAL REQUIREMENT(BOM)MATERIAL REQUIREMENT(BOM)OPERATION DRAWINGSOPERATION DRAWINGSPRODUCT COST ESTIMATION AND QUOTATIONPRODUCT COST ESTIMATION AND QUOTATIONCREATING AND MAINTAINING EDMCREATING AND MAINTAINING EDMCODIFICATION FOR PARTSCODIFICATION FOR PARTSFIRST OFF PROVINGFIRST OFF PROVING
PROGRAMME ENGG
SCHEDULING PROGRESS
SCHEDULINGSCHEDULING
IT IS A TIME TABLE OF PRODUCTION IT IS A TIME TABLE OF PRODUCTION PLAN TO MEET THE CUSTOMER PLAN TO MEET THE CUSTOMER DEMANDDEMAND
SCHEDULINGSCHEDULING
1.1. LAUNCHING OF PRODUCTS BASED LAUNCHING OF PRODUCTS BASED ONON
A.A. CAPACITY AVAILABLECAPACITY AVAILABLE
B.B. DELIVERY SCHEDULEDELIVERY SCHEDULE
C.C. LEAD TIMELEAD TIME
D.D. BUILD SEQUENCEBUILD SEQUENCE
E.E. BATCH QTYBATCH QTY
SCHEDULINGSCHEDULING
BASIC DOCUMENTS USEDBASIC DOCUMENTS USED
A.A. PRODUCTION PLANPRODUCTION PLAN
B.B. DELIVERY SCHEDULEDELIVERY SCHEDULE
C.C. MASTER SCHEDULEMASTER SCHEDULE
SCHEDULINGSCHEDULING
MASTER SCHEDULES ARE DRAWN FORMASTER SCHEDULES ARE DRAWN FOR• RELEASE OF JOB CARDSRELEASE OF JOB CARDS
• DUE FOR LOADINGDUE FOR LOADING• DUE FOR COMPLETIONDUE FOR COMPLETION
SCHEDULINGSCHEDULING
WORK ORDERSWORK ORDERS
ASSIGNED TO EACH PROJECT FOR ASSIGNED TO EACH PROJECT FOR • COST COLLECTIONCOST COLLECTION
• MATERIAL AND LABOUR MATERIAL AND LABOUR ACCOUNTINGACCOUNTING
SCHEDULINGSCHEDULING
JOB ORDER DOCUMENTSJOB ORDER DOCUMENTS
• JOB TICKETJOB TICKET• ROUTE CARDROUTE CARD
• PROGRESS CARD PROGRESS CARD • MATERIAL REQUISITION(DETAIL/ASSY)MATERIAL REQUISITION(DETAIL/ASSY)
• JOB ORDERS ARE PRINTED ON LINE JOB ORDERS ARE PRINTED ON LINE BASING ON THE EDM DATABASING ON THE EDM DATA
PROGRESSPROGRESS
PARTS ARE LOADED FOR MANUFACTURING PARTS ARE LOADED FOR MANUFACTURING COVERING VARIOUS PROJECTS BASING ON DUE COVERING VARIOUS PROJECTS BASING ON DUE FOR LOADING SCHEDULEFOR LOADING SCHEDULE
JOB PREPARATION IS DONE IN ADVANCE FOR JOB PREPARATION IS DONE IN ADVANCE FOR PROGRAMMED PARTS BY CHECKING AVAILABILITY PROGRAMMED PARTS BY CHECKING AVAILABILITY OF :OF :
- DRAWINGS- DRAWINGS - TOOLS- TOOLS - MATERIALS- MATERIALS - MACHINE- MACHINE
PROGRESSPROGRESS
CLOSE FOLLOW UPS WITH THE CLOSE FOLLOW UPS WITH THE MANUFACTURING SHOPS ARE MAINTAINED MANUFACTURING SHOPS ARE MAINTAINED TO ENSURE COMPLETION OF PARTS AS PER TO ENSURE COMPLETION OF PARTS AS PER PLANPLAN
PERIODIC PRODUCTION HOLDUP REPORTS PERIODIC PRODUCTION HOLDUP REPORTS ARE GENERATED ARE GENERATED
- MATERIAL SHORTAGES- MATERIAL SHORTAGES - NON AVAILABILITY OF TOOLS- NON AVAILABILITY OF TOOLS - MACHINE BREAKDOWN- MACHINE BREAKDOWN
PROGRESSPROGRESS
AFTER THE COMPLETION AND AFTER THE COMPLETION AND TAGGINGTAGGING
• THE PARTS ARE STORE CREDITEDTHE PARTS ARE STORE CREDITED• AND THE CORRESPONDING WORK AND THE CORRESPONDING WORK
ORDERS ARE CLOSEDORDERS ARE CLOSED
PPCPPC
THE PROGRAMME ENGG GROUP’S THE PROGRAMME ENGG GROUP’S MAIN FUNCTIONS ARE:MAIN FUNCTIONS ARE:
SCHEDULINGSCHEDULING
PROGRESSPROGRESS
Production Tool Stores
Finance
Management Services
Inspection
Receiving Stores
Holding Stores
Customer Support
Methods Material Control Purchase
Production Control
Scheduling
Tool Engineerin
g
External Sources Manufacturing/
Assembly shop
Labour, WLS
PDO’s
STAC
MDP
QMS
STAC
STAC
SLIM, STAC, SDG
SDG, PPRS
SDG
STORE ACCOUNTING
PRD COST EST
BILL OF MATLS
WOC
SDG, PPRS
SDGSTAC
MDP
ORDER PROCESSING SYSTEM
BOM
MDP
MDP, BOM, QMS
MPAC
POPS
POPS
WIP, WLS
TMS
WIP
LABOUR BOM
MDP
MDP
POPS
BOM, SDG PPRS
MDP
STORE A/C
STAC
PRODUCTION PLANNING AND CONTROL SYSTEM
PPC SYSTEMPPC SYSTEMMDP – MASTER DATA PROCESSORMDP – MASTER DATA PROCESSORPPRS – PLANNED PARTS REQUIREMENT SYSTEMPPRS – PLANNED PARTS REQUIREMENT SYSTEMBOM – BILL OF MATERIALSBOM – BILL OF MATERIALSSDG – SHOP DOCUMENT GENERATORSDG – SHOP DOCUMENT GENERATORMPAC – MATERIAL PROVISIONING ACCOUNTING AND CONTROLMPAC – MATERIAL PROVISIONING ACCOUNTING AND CONTROLTMS – TOOL MONITORING SYSTEMTMS – TOOL MONITORING SYSTEMSTAC – STORE ACCOUNTINGSTAC – STORE ACCOUNTINGPCE – PRODUCT COST ESTIMATIONPCE – PRODUCT COST ESTIMATIONSLIM – SHELF LIFE INFORMATION MONITORINGSLIM – SHELF LIFE INFORMATION MONITORINGWLS – WORK LOAD SIMULATIONWLS – WORK LOAD SIMULATIONPDOs – PART DISPOSITION ORDERSPDOs – PART DISPOSITION ORDERSWIP – WORK IN PROGRESSWIP – WORK IN PROGRESSORP – ORDER PROCESSINGORP – ORDER PROCESSINGWOC – WORK ORDER CONTROLWOC – WORK ORDER CONTROLPOPS – PURCHASE ORDER PROGRESS SYSTEMPOPS – PURCHASE ORDER PROGRESS SYSTEMQMS – QUALITY MANAGEMENT SYSTEMQMS – QUALITY MANAGEMENT SYSTEM
EDM SYSTEMEDM SYSTEM
PRODUCTIONDOCUMENTS
PLANNINGBREAK DOWN
CYCLE TIMEFOR PARTS
LEAD TIMEFOR PARTS
PRICINGDETAILS
MATERIALSUMMARY
ASSEMBLYOPN SHEETS
WORK LOADDETAILS
TOOLINGINFORMATION
EDM
EDM FORMS THE HUB OF PPC SYSTEM
CODIFICATION MASTERCODIFICATION MASTER
RATIONAL CODES ARE GENERATED RATIONAL CODES ARE GENERATED FORFOR
FABRICATED PARTSFABRICATED PARTS
BOUGHT OUT PARTSBOUGHT OUT PARTS
STANDARD PARTSSTANDARD PARTS
CONSUMABLESCONSUMABLES
FORGINGS AND CASTINGSFORGINGS AND CASTINGS
RAW MATERIALSRAW MATERIALS
PART MASTERPART MASTER
RAW MATERIAL DETAILS INCLUDING SIZE RAW MATERIAL DETAILS INCLUDING SIZE AND SPECIFICATIONAND SPECIFICATION
REFERENCE DRAWING DETAILSREFERENCE DRAWING DETAILS
NEXT ASSEMBLY DETAILSNEXT ASSEMBLY DETAILS
DEPT,CATEGORY,QPA,LMS,STORE DETAILSDEPT,CATEGORY,QPA,LMS,STORE DETAILS
APPLICABALITY OF PARTS/ASSEMBLIESAPPLICABALITY OF PARTS/ASSEMBLIES
PART CODE/RAW MATERIAL CODEPART CODE/RAW MATERIAL CODE
SPECIAL INSTRUCTIONS APPLICABLE FOR SPECIAL INSTRUCTIONS APPLICABLE FOR PARTS PARTS
ROUTING MASTERROUTING MASTER
DEPARTMENT WORK CENTRE DEPARTMENT WORK CENTRE DETAILSDETAILS
TOOLING DETAILSTOOLING DETAILS
OPERATION DETAILSOPERATION DETAILS
SEQUENCE OF OPERATIONSSEQUENCE OF OPERATIONS
RATE FIXINGRATE FIXING
SETUP TIMESETUP TIME
UNIT TIMEUNIT TIME
ASSEMBLY MASTERASSEMBLY MASTER
PARTS REQUIRED FOR ASSEMBLYPARTS REQUIRED FOR ASSEMBLY
CATEGORY AND QUANTITY PER ASSYCATEGORY AND QUANTITY PER ASSY
APPLICABILITY RESTRION OF PART APPLICABILITY RESTRION OF PART FOR THE ASSEMBLYFOR THE ASSEMBLY
PART CODEPART CODE
CONSUMABLESCONSUMABLES
SCHEDULING
ORP EDM
SDG
WOC
BOM
SFM
WLS PPRSWIP
SCHEDULING SYSTEM IS AN INTREGRATION OF VARIOUS SUB MODULES MODULES ARE USER DRIVEN
SCHEDULING SYSTEM
BILL OF MATLS
PLANNED PARTSREQUIREMENT SYS
WORK ORDERCONTROL
SHOP DOCUMENTGENERATOR
ENGINEERINGDATA MASTER
ORDER PROCESSINGBILL OF MATLS
SHOP FLOORMANAGEMENT
WORK LOADSIMULATION
WORK IN PROG
PPRS PPRS (PLANNED PARTS REQUIREMENT SYSTEM)
PPRS
BOM
EDM
SLT/CLT/CTSOS REPORT
DEL DATE
WIPMASTERSCHEDULE
BASED ON END PRODUCT DELIVERY DATE AND LEAD TIME OF MANUFACTURE, DETAILED PARTS MANUFACTURING SCHEDULES AREGENERATED BY COMPUTER
ORDER PROCESSING ORDER PROCESSING MODULEMODULE
MODULE OPERATED BY CUSTOMER MODULE OPERATED BY CUSTOMER SERVICES AND SCHEDULING DEPTSSERVICES AND SCHEDULING DEPTS
MONITORS ORDER BOOK STATUSMONITORS ORDER BOOK STATUS
BILL OF MATERIAL MODULEBILL OF MATERIAL MODULE
BILL OF MATERIAL FOR ANY END BILL OF MATERIAL FOR ANY END PRODUCTPRODUCT
CONSOLIDATED AS WELL AS DETAIL CONSOLIDATED AS WELL AS DETAIL MATERIAL SUMMARYMATERIAL SUMMARY
PPRS MODULEPPRS MODULEGROSS AND NET REQUIREMENT OF PARTS ARE GENERATEDGROSS AND NET REQUIREMENT OF PARTS ARE GENERATEDBACKWARD SCHEDULING BASED ON END PRODUCT DELIVERY DATE BACKWARD SCHEDULING BASED ON END PRODUCT DELIVERY DATE
GENERATED WITH CYCLE TIME AND LEAD TIME DATAGENERATED WITH CYCLE TIME AND LEAD TIME DATAASSEMBLY SHORTAGES ARE GENERATEDASSEMBLY SHORTAGES ARE GENERATEDCOMPREHENSIVE DETAILED AND CONSOLIDATED MIS REPORTS COMPREHENSIVE DETAILED AND CONSOLIDATED MIS REPORTS
GENERATEDGENERATED 1. JIG LOADING PLAN1. JIG LOADING PLAN 2. DUE FOR RELEASE2. DUE FOR RELEASE 3.DUE FOR LOADING3.DUE FOR LOADING 4. DUE FOR COMPLETION4. DUE FOR COMPLETION 5. MODULES WISE/STAGEWISE/DEPTWISE SHORTAGE LISTS5. MODULES WISE/STAGEWISE/DEPTWISE SHORTAGE LISTS 6. SOS REPORTS 6. SOS REPORTS 7. ETC.7. ETC.
SHOP DOCUMENT SHOP DOCUMENT GENERATORGENERATOR
USER DRIVEN SYSTEMUSER DRIVEN SYSTEM
GENERATES PRODUCTION GENERATES PRODUCTION DOCUMENTS ON LINEDOCUMENTS ON LINE
NO MANUAL MAINTAINANCE OF NO MANUAL MAINTAINANCE OF DOCUMENTSDOCUMENTS
WIPWIP
MAINTAINS STATUS OF ALL WORK MAINTAINS STATUS OF ALL WORK ORDERS THROUGHOUT THE ORDERS THROUGHOUT THE PRODUCT CYCLE- WORK ORDER PRODUCT CYCLE- WORK ORDER RELEASE TO STORE CREDITRELEASE TO STORE CREDIT
AUTOMATIC WORK ORDER CLOSUREAUTOMATIC WORK ORDER CLOSURE
SHOP FLOOR MANAGEMENTSHOP FLOOR MANAGEMENT
AUTOMATIC UPDATION OF WIP FILEAUTOMATIC UPDATION OF WIP FILE
WORK LOAD SIMULATIONWORK LOAD SIMULATION
DEPT WISE/WC WISE LOAD IS DEPT WISE/WC WISE LOAD IS COMPUTED FOR PARTSCOMPUTED FOR PARTS
• DUE FOR LOADINGDUE FOR LOADING• PARTS ANTICIPATED FOR LOADINGPARTS ANTICIPATED FOR LOADING• AVAILABLE CAPACITY VS WORK LOADAVAILABLE CAPACITY VS WORK LOAD
PPCPPC
WHAT IS IN STORE FOR WHAT IS IN STORE FOR FUTURE ?FUTURE ?
ERPERP
ERP INTEGRATES INFORMATION ERP INTEGRATES INFORMATION ACROSS DEPARTMENTS AND ACROSS DEPARTMENTS AND PROVIDE A SET OF TOOLS FOR PROVIDE A SET OF TOOLS FOR PLANNING AND MONITORING THE PLANNING AND MONITORING THE VARIOUS FUNCTIONS AND VARIOUS FUNCTIONS AND PROCESSES AND PROGRESS PROCESSES AND PROGRESS TOWARDS THE COMMON PURPOSE TOWARDS THE COMMON PURPOSE
OTHERSOTHERS
LEANLEAN
SCMSCM
TQMTQM
KAIZENKAIZEN
INVENTORY MANAGEMENTINVENTORY MANAGEMENT
WORLD CLASS ORGANISATIONWORLD CLASS ORGANISATION
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