Production Planning and Control

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  • Topic: Manufacturing resource planning, Production system, Inventory
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PEMP EMM2517

Session 15 PPC in Pull Production
Lecture delivered by: Vijaya Kumar S Kumar. Asst. Professor MSRSAS. MSRSAS S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

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Session Objectives
At the end of the session the delegate would have understood:  Requirements of PPS in a Pull System. g y p  How to design a new PPS system or adapt an existing planning system to a Pull environment.

S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

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Push & Pull Systems

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• What is a Push system of production? In a traditional setup execution of a sales demand is setup, achieved by the use of work orders, which authorize the release for manufacturing in lot sizes, pre-decided, g ,p , and subsequent assembly. This system is referred to as push systems, since each work order is tracked and pushed through a series of work centers. Results in excessive inventory between work centers. In I a pull system all work centers are activated only ll ll k i d l when there is a withdrawal/consumption. S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

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Push & Pull Comparison p
sales mps final M R P f
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Info matl

s
ka

sub fab

S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

PEMP EMM2517

Continued
• Pull production system is also called JIT production OR stockless production. p • Though this system will help in reduction of WIP, it is not possible to produce with no in-process inventory. Some inventory must be held in the buffers • Other conditions for pull production are: • More responsibility for short term planning & control must be with shop supervisors/workers. • Everywhere reduction of inventory & Production=Demand must be practiced. M.S Ramaiah School of Advanced Studies - Bangalore 5

S. Vijaya Kumar, MSRSAS

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Continued
Minimum b/downs by PM & TPM. Total quality assurance by prevention. Setup times must be small Layout must facilitate linking of operations and smooth flow/as balanced a cap as possible. • Leveled production schedules • Cooperative team work must be built. working. • Kaizen must be a way of working S. Vijaya Kumar, MSRSAS

• • • •

M.S Ramaiah School of Advanced Studies - Bangalore

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Manufacturing Planning and Control System
Resource planning Production planning Demand mgt

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MPS Detailed Cap plan Detailed Matl plan Matl and cap plans Shop-floor system Vendor system M.S Ramaiah School of Advanced Studies - Bangalore

Front end

Engine

S. Vijaya Kumar, MSRSAS

Back end
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Constituents of a PPS in Pull
• Having understood the basics of Pull Systems ,PP&C for a Pull environment is divided into centralized & de-centralized de centralized components. • Push system depend on MRP type system for long range decisions which are definitely required in a pull scenario also • Centralized part of the system performs Order entry demand forecasting, RCCP,MPS MRP. forecasting RCCP MPS & MRP • See the links with Plant/process improvement during RCCP • Level MPS in a dynamic manner, daily production schedules y , yp to the final stage with corrections.( balanced between customer demand and need of leveling them.) S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

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PEMP EMM2517

Continued
• Centralized Manufacturing Control Central control system Information flow

Manufacturing facilities g
Control is from above. There is an attempt to determine / plan. Work load of individual m/cs. So massive data collection Updating are required S. Vijaya Kumar, MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore

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Continued
• Distributed manufacturing control.
Simple manu control system

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Info flow
Product cell Product cell Product cell Product cell

Different, detailed local control...
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