APICS Certified in Production and Inventory Management (CPIM): Execution and Control of Operations Courseware Update Presented by David F. Ross, Ph.D., CFPIM, CSCP APICS Professional Development
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APICS Certified in Production and Inventory Management (CPIM): Execution and Control of Operations Courseware UpdatePresented by David F. Ross, Ph.D., CFPIM, CSCPAPICS Professional Development
Slide-2
Summary of Changes• Reduced from nine to eight sessions
• Significant graphical changes to PowerPoints
• Significant graphical changes to Instructor Guide (IG) and Participant Workbook (PW)
• Increased use of case studies and in-text questions
• Updated performance check questions
• ECO text reference changes
• Revised IG introduction
• Session-by-session review
• Urged to consult the new APICS CPIM ECO Exam Content Manual (ECM)
Slide-3
APICS CPIM Courseware Module Image Change
Slide-4
Instructional Design Changes• PowerPoints updated to match APICS CPIM Basics of
Supply Chain Management (BSCM), Strategic Management of Resources (SMR), and Detailed Scheduling and Planning (DSP)
• IG and PW updated to match BSCM, SMR, and DSP courseware books
• Enhancement of learning objectives
• Expanded use of tables
• Use of student in-text questions and problems
• Updated end-of-session performance check
Slide-5
ECO ReferencesTextbooks:
• Arnold et al., Introduction to Materials Management, 6th ed.• Dennis, Lean Production Simplified, 2nd ed.
• Garrison et al., Managerial Accounting, 12th ed.
• Gryna et al., Juran’s Quality Planning & Analysis for Enterprise Quality, 5th ed.
• Jacobs et al., Manufacturing Planning & Control Systems for Supply Chain Management, 6th ed.
• Liker, The Toyota Way, 2004.
• Ross, Distribution Planning and Control, 2nd ed.• Slack et al., Operations and Process Management, 2nd ed.
• Wallace, T., Sales and Operations Planning, The How-To Handbook, 3rd ed.
Slide-6
Text and ECM References
Text
references
linked to ECM
Slide-7
New IG Introduction
Slide-8
ECO Course RoadmapSessions:
1. Execution of Operations2. Scheduling and
Authorization3. Control of Production4. Control of Costs and Quality5. Management and
Communication6. Quality and Continuous
Improvement7. Design Trade-offs8. Case Studies and Review
Activity
Slide-9
Sessions:1. Execution of Operations2. Scheduling and Authorization3. Control of Production4. Control of Costs and Quality5. Management and Communication6. Quality and Continuous
Improvement7. Design Trade-offs8. Case Studies and Review Activity
Comparing V2.4 and V3 −−−−OverviewSessions:1. Planning, Execution, and Control
Overview2. Scheduling Production and Process
Operations3. Authorizing, Executing, and Reporting
Activities for Push Systems4. Authorizing, Executing, and Reporting
Activities for Pull Systems5. Communicating Customer-Supplier
Information and Controlling Resources6. Quality and Continuous Improvement
Initiatives–Basic Concepts7. Quality and Continuous Improvement
Initiatives–Making It Happen8. Quality Management Processes9. Evaluating Performance of Production
Operations
Slide-10
Session 1V.2.4 V3.0
Pages 57 45
Overheads 43 45
Session 1: Planning, Execution, and Control Overview
The Manufacturing Planning and Control System
Manufacturing Planning and Control Activities
Operating Environments
Session 1: Execution of Operations
Manufacturing Planning
Defining Execution and Control Systems
Version 2.4 Version 3.0
Slide-11
Session 1–Content Changes
• V.3 enhanced discussion of MPC system• Link to APICS CPIM exams• Discussion centered on batch versus flow
production• Introduction of push versus pull concepts• Introduction of materials requirements planning
(MRP)-based and lean/Just-in-time (JIT) based systems
• Decreased process layout discussion
Slide-12
Session 2V.2.4 V3.0
Pages 75 57
Overheads 49 50
Session 2: Scheduling Production and Process Operations
What Is a Schedule?Establishing a ScheduleProduction SchedulingScheduling Production and Process
OperationsManaging the Operations ScheduleImproving the Flow
Session 2: Scheduling and Authorization
MRP-Based SchedulingTheory of Constraints (TOC)
SchedulingLean/JIT Scheduling
Version 2.4 Version 3.0
Slide-13
Session 2–Content Changes• Discussion change from make-to-stock, assemble-to-
order, and make-to-order to MRP-based, TOC, and lean/JIT based scheduling
• Enhanced discussion of operation setbacks, Gantt charts, forward/backward scheduling, infinite/finite loading, and priority control/sequencing of operations
• Slack time and critical ratio exercises
• New TOC section
• New lean/JIT scheduling section
• Removal of sections on lead time, lot size, and maintenance
Slide-14
Session 3V.2.4 V3.0
Pages 69 83
Overheads 51 61
Session 3: Authorizing, Executing, and Reporting Activities for Push Systems
What Is a Push System?Authorizing ActivitiesExecuting ActivitiesReporting Activities
Session 3: Control of Production
Scope and Principles of Operations ControlProduction Activity Control: MRP-BasedProduction Activity Control: Lean/JIT BasedInventory Management Issues
Version 2.4 Version 3.0
Slide-15
Session 3–Content Changes• V.3 change from push and pull concept to MRP-based and
lean/JIT-based scheduling concept
• Discussion of MRP-based and lean/JIT-based scheduling in the same session. Reduction from V.2.4
• In MRP-based section, discussion of input/output control, priority control, constraints, lead times, overlapping, and lot splitting
• In lean/JIT-based section, discussion of heijunka, takt time, pacemaker, store (supermarket), kanban system, and documentation
• Inventory management section moved from V.2.4 session 5
Slide-16
Session 4V.2.4 V3.0
Pages 67 69
Overheads 36 54
Version 2.4 Version 3.0
Session 4: Authorizing, Executing, and Reporting Activities for Pull Systems
What Is a Pull System?
Authorizing Activities
Executing Activities
Reporting Activities
Session 4: Control of Costs and Quality
Cost Control
Control of Quality
Slide-17
Session 4–Content Changes• Discussion of pull scheduling removed, shortened, improved,
and placed in session 3 on V.3.
• Session dedicated to discussions on manufacturing cost and quality management
• New section on cost control: overhead costing, job-order vs. process costing, absorption vs. variable costing, traditional product vs. ABC costing, actual vs. standard costing, and types of quality costing
• New section on control of quality: sporadic vs. chronic quality problems, sampling methods, causes and management of variation, statistical process control (SPC) charting, and process capability calculation
Slide-18
Session 5V.2.4 V3.0
Pages 57 53
Overheads 39 40
Session 5: Communicating Customer-Supplier Information and Controlling Resources
Communicating Customer-Supplier InformationSharing InformationData CommunicationControlling Storage and Movement of Materials
Session 5: Management and Communication
Approaches to ManagementWorker DevelopmentWorker Participation/Involvement
Version 2.4 Version 3.0
Slide-19
Session 5–Content Changes• V.2.4 discussion on customers/suppliers shortened and
moved to V.3 session 7.
• V.2.4 discussion on inventory/warehousing moved to V.3 session 3
• V.3 new session on management issues: scientific management, worker self-control, and quality management leadership
• V.3 new session on worker development: teams, job-enrichment, empowerment, performance appraisal from V2.4 session 6
• V.3 new session on worker participation/involvement: kaizen circle and kaizen training from V.2.4 session 6
Slide-20
Session 6V.2.4 V3.0
Pages 95 57
Overheads 50 47
Session 6: Quality and Continuous Improvement Initiatives–Basic Concepts
Executing Quality Initiatives, Eliminating Waste, and Implementing Continuous Improvement PlansQuality and Continuous Improvement ToolsDeveloping, Evaluating, and Rewarding People
Session 6: Quality and Continuous Improvement
The Seven Basic Quality ToolsSix Sigma design-measure-analyze control (DMAIC)Plan-do-check-action (PDCA) CycleA3 Problem Solving
Version 2.4 Version 3.0
Slide-21
Session 6–Content Changes
• Shortening of quality tools from V.2.4.
• Some shortened topics on quality management moved from V.2.4 session 8 to V.3 session 6
• Removal of V.2.4 sections on worker management to V.3 session 5.
• Updates sections on basic quality tools, six sigma DMAIC, PDCA cycle, and A3 problem solving
Slide-22
Session 7V.2.4 V3.0
Pages 45 77
Overheads 21 54
Session 7: Design Trade-offs
Design PrinciplesDesign Techniques
Version 2.4 Version 3.0
Session 7: Quality and Continuous Improvement Initiatives–Making it Happen
Process ImprovementMethods of Process ImprovementMethods of Eliminating Waste
Slide-23
Session 7–Content Changes• V.2.4 session practically eliminated from the course
• New sections on design principles: impact on intermittent and mass production processes, relationships with customer/suppliers, impact on production processes and layouts, and global design principles
• Import of design principles from V.2.4 session 8 to V.3 session 7
• V.3 updates to supply network flow, sourcing/ outsourcing, role of market research, quality functional deployment (QFD), workplace layout
Slide-24
Session 8V.2.4 V3.0
Pages 89 50
Overheads 52 31
Session 8: Case Studies and Review Activity
Case StudiesWiki Review Activity
Version 2.4 Version 3.0
Session 8: Quality Management Processes
Quality Management ProcessesConcept of VariationStatistical Quality ControlStatistical Process Control ChartsProcess Capability AnalysisIncoming InspectionMonitoring Supplier Performance
Slide-25
Session 8–Content Changes
• V.2.4 entirely removed, broken up, and spread throughout V.3.
• New V.3 multipart case study that presents a simplified scenario of planning a transition to lean/JIT production.
• New V.3 review Wiki activity to reinforce and review topics discussed during the course.
Slide-26
Wiki Activity• Second half of last session
• Students work collaboratively to build a knowledge base on several topics (similar to Wikipedia approach)
• Students write mock exam questions
• Students take the mock exam
• Added as appendix to MPR, ECO, DSP, and SMR
Slide-27
Session 9V.2.4 V3.0
Pages 87
Overheads 53
Session 9: Evaluating Performance of Production Operations
Evaluating Performance of Production Operations
Accuracy of Inventory RecordsPerformance ReportingEvaluating Cost of OperationsAudits and ReportingQuality Audits
Version 2.4 Summary
V.2.4 V3.0
Pages 641 491
Overheads 394 382
Removed and shortened material dispersed throughout V.3
Slide-28
Questions?
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