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Session 2: Session 2: Basics of Production PlanningBasics of Production PlanningTypes of Production Planning Types of Production Planning ScenariosScenarios
Atanu GhoshAtanu [email protected]@nevaehtech.com
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PPC: The Big Picture PPC: The Big Picture
Business planning• Budgeting
• Sales planning
• Profitability planning
• Product planning
Production planning• Planning strategy
• MPS/ MRP
• Rough-cut capacity planning
Shop floor planning• Scheduling
• Maintenance planning
• Detailed capacity planning
• Raw material purchase planning
• Spares planning
• Personnel planning
Production execution• BOM, Routing and Work Center Design
• Production recording
• Time recording
• Cost recording
• Quality inspection
MES• Interface with PLCs
• Interface with time recording system
Top floor
Shop floor
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Types of manufacturing Types of manufacturing
• Production of discrete components manufactured and assembled in a “piece by piece” fashion
• Mostly made to order or engineered to order
• Examples – automobiles, industrial machinery and components, white goods, etc
Discrete manufacturing
Process manufacturing
Repetitive manufacturing
Project manufacturing
• Continuous production but separable in “batches”
• Each batch is run for specified period
• Examples – pharmaceuticals, chemicals, oil, steel
• Same or similar products produced over a lengthy period of time
• Goods produced are not manufactured in individually differentiable lots
• Examples – cement, iron, electronic chips
• Production of large engineering products
• Usually engineered to order
• Examples – aircraft, ship building, turbine manufacturing
Complex
Simple
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Project manufacturing Project manufacturing
Data Management(ship system breakdown structure, parts, CAD drawings)
Business Management(Financial and Human Resources)
Business Management(Financial and Human Resources)
Conceptdesign
Functionaldesign
DetailDesign
ProcurementFabrication Assembly
Pre-order Order Execution
Project managementProject management
Globalization
CollaborationFabrication& AssemblyProcurement
Functional & DetailDesign
Concept Design
Globalization
CollaborationFabrication& AssemblyProcurement
Functional & DetailDesign
Concept Design
Conceptdesign
Functionaldesign
DetailDesign
Conceptdesign Conceptdesign
Functionaldesign
Functionaldesign
DetailDesignDetail
Design
ProcurementFabrication Assembly
ProcurementFabrication Assembly
Document ManagementClassificationProduct StructureChange ManagementWorkflowCollaborative EngineeringCAD/ERP integration
Document ManagementClassificationProduct StructureChange ManagementWorkflowCollaborative EngineeringCAD/ERP integration
Project Management ProcurementDemand AggregationChange ManagementProgress TrackingProduction managementActual labour costingQuality AssuranceCost & cash management
Project Management ProcurementDemand AggregationChange ManagementProgress TrackingProduction managementActual labour costingQuality AssuranceCost & cash management
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Project manufacturing Project manufacturing
Preliminary Design
Detail Design
Steel-Cutting
Painting & Erection
time
Procurement
Hull Assembly and pre-outfitting
Outfitting
Sea trials
Preliminarydesign phase
Detail design, Procurement, Production phase
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Project manufacturing Project manufacturing Project Specific Manufacturing
Interactive and concurrent process between design, procurement and production
Low level of detail information at the beginning of the project
Cost control against ship system breakdown structure
Deadlines for purchase and production controlled by a project plan
Procurement of complex components is a collaborative process between designers and suppliers
Early procurement of “key” components
Outfitting process managed by palletising of materials
Quality control of procured materials and production activities (welding , painting, outfitting etc.)
Sub-contractors management
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Discrete manufacturing Discrete manufacturing
Incoming payment
Profitability analysis
Product costing
Webshop
Sales and service
Quality/compliance
Purchasing
Finance/controlling
Supply chain planning/ warehouse/logistics
Manufacturing
Research and development
Sales and service
Quality/compliance
Purchasing
Finance/controlling
Supply chain planning/ warehouse/logistics
Manufacturing
Research and development
MRP and capacity planning
Demand planning
Sales orderprocessing Manufacturing Delivery Billing
Purchase order
processing
Order-to-cash
Corporate services/financials/controlling
Quality management/compliance
Delivery Invoice
Procurement
Outgoing payment
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Discrete manufacturing Discrete manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Process manufacturing Process manufacturing
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Repetitive manufacturing Repetitive manufacturing
Cement Plant
Proportioning, blending, and grinding
Preheater tower
Kiln
Clinker cooler and finishing grindings
Ready-mix plant
CementQuarry
Direct sales
Wholesale
Construction site
Fuel Electricity
Aggregates Additives
Cement Plant
Proportioning, blending, and grinding
Preheater tower
Kiln
Clinker cooler and finishing grindings
Ready-mix plant
CementQuarry
Direct sales
Wholesale
Direct sales
Wholesale
Construction site
Fuel Electricity
Aggregates Additives
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Repetitive manufacturing Repetitive manufacturing
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Repetitive manufacturing Repetitive manufacturing
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Repetitive manufacturing Repetitive manufacturing
23232121--MarMar--0909
Next Session: BOM, Routing Next Session: BOM, Routing and Work Centerand Work Center
Atanu GhoshAtanu [email protected]@nevaehtech.com
