PROCESS MAPING FOR PRODUCTION PLANNING PROCESS

Sl. Process INPUT ACTIVITIES OUTPUT

I Monthly Production PReceipt of SKU wise requirement from Work out SKU'S wise total requirement
Customer at marketing including overseas and plott the same machine Tentative monthly plan
a)From Priority customer for own wise considering schedule of customers. ( Overseas requiremnt will be
region & other regions put in Green siganl only on
receipt of LC / Confirm PO)
b) General market requirement based
on previous trends and current
demand
c)Enquiry form overseas customer
NPD Requirement to be considered
II Draft Production Tentative Monthly Plan from Mktg for Preparation of Draft Plan for the month 1.Draft Monthly Prodution Plan
Plan & Draw pattern all three furnaces with machinewise considering following. 2. Draw Pattern
Loading plan and quantity requirement.

Allocation and sequencing of SKU's on

different lines considering following factors
1.Weight / Capacity of SKU's ( similar jobs on
same line)
2. Market requirement from Marketing.
3. FG stock statement. .
4. Mould life. & availability statement.
5. Neckring availibilty in non std. cases
6. New Mould delivery schedule
7. NPD trial status
8. Forehearth Capacity for required draw for
the bottles.
9. Performance of previous runs of jobs on
different lines. / Action Plan or consider
previous job average efficiency for run
Sl. Process INPUT ACTIVITIES OUTPUT
10. Packing material availibility on run date
specially in case of Spl. papers for oveseas
requirement .
11. Not more than one job change in a day per
furnace in general
12. Run Qty of Export jobs to be Palnned
13. Moulds & Equipments from Other Plants (
in case of Common jobs) should be made
available.
III Monthly Plan 1.Draft Monthly Prodution Plan 1.Job On meeting Monthly Production Plan
2. Draw Pattern 2. Final Review by mktg (after incorporating changes
suggested by Works or
marketing after consultation)
IV Green Signal Monthly Production Plan Preparation of Green Signal , which is firm Job Green Signal
change plan for 10 days ( 3 GS in a Month)

Factors to Consider
1. Efficiency of running Jobs on all lines
2. Any change in schedule or requirement by
Marketing /customer.
3. Receipt of LC or Firm order for overseas
requirement.
4.Urgent requirements of customers which may
or may not be in monthly plan
5. Average efficiency in case of Export jobs to
be considered to find out exact run days.
6. Furnace condition in terms of seed & Blister
is to be considered before inserting LW Jobs in
Amber
7.Flexibility in last two days of third green signal
for optimising T1 & T2 time.
8. Moulds & Other Equipment including
Packing materrial should be available before
Job change.
Sl. Process INPUT ACTIVITIES OUTPUT
9. Modification Planned if any must be carried
out before Job change.
10. Provision for any Major maintenance
activity should be made in green Signal and
other JC to be alligned accordingly