Production Planning

Scheduling production Manufacturing production Controlling production activities

Scheduling Production

Before production begins the manager must know what product is being produced and how many. This information is gained through production planning and control personnel

Scheduling Production 4 Main Tasks

Routing: deciding where the work is to be done Scheduling: deciding when the work is to be started and completed Dispatching: issuing work orders to start actual production Expediting: seeing that the work is progressing on schedule

Routing Production

Routing depends on the type of manufacturing being used.

Continuous manufacturing routes are built into the factory layout.

The product moves along fixed paths from station to station

Intermittent and custom manufacturing plants group the equipment by function.

Routing Production

The path of materials through the manufacturing facility are shown on a flow diagram.

Routing Production

A line production routing sheet is used by managers to monitor total production schedules. It includes:

A description of the operation The product rate in pieces per hour The number of operators and machines needed The cost of producing the product in standard units

Scheduling Production

The line production routing sheet is used to help schedule. The goal is to use 100% of the manufacturing plant. Schedules are based on:

Sales forecasts by day, week, and month for each product Inventory levels for both raw materials and finished products Manufacturing capacity to be schedules in terms of the number of products that can be produced per hour or day

Schedules determine the parts or products that should be manufactured each day the plant operates

Scheduling Production

Production schedules most also consider lead time, including the time it takes to:
Order and receive materials and parts that must be purchased Make parts from materials Assemble parts into products Package products for delivery

Dispatching and Expediting

Dispatching involves releasing daily or weekly schedules Expediting involves keeping the product on schedule with daily product reports

If the schedule is broken, corrective action might include:

Overtime Retraining workers Changing operations to improve efficiency Holding a motivational meeting

Manufacturing Production

After scheduling, the products must be produced. They run through 2 types of production:

Pilot production Manufactures test the new production lines before placing the product in full production

Corrections for problems might include: product designs, tooling designs, production methods, plant layouts, and material handling system

Full Scale production this is where the efficient manufacturing takes place

Manufacturing Production

When changes are made to the flow process, it is done on a flow process chart.

Controlling Production Activities

There are 3 major categories of information for controlling production:

Production data this is a report that lists the number of products schedules to be built, the number of products started, the number of products scraped, and the number of products completed. Inspection data - comes from 3 types of inspection: material, in-work, and finished product inspection. Inspectors check materials as they move through the process Payroll data this is the pay to the employees for the completed work.