6 Steps Of Production Planning And Control The distribution of labor, raw materials, workspaces, equipment, and production procedures is managed and scheduled by production planning and control. It determines the most cost-effective method of producing final items within the lead times required to satisfy manufacturing demand.In manufacturing, two tactics that complement one other are production planning and control. Planning includes determining what should be produced, when, how much, and other details. By employing various control strategies to improve throughput targets, production control guarantees the production system operates at its best.
6 Steps Of Production Planning And Control
6 Steps Of Production Planning And Control, The terms production planning and control and production control apply to the two distinct pre-production phases of manufacturing. It is the process of controlling the labor force, schedules, resources, and other elements involved in the production of goods and services. Businesses use production planning and control to improve their manufacturing process and keep setbacks from interfering with regular business operations.
What is production planning
6 Steps Of Production Planning And Control, By effectively managing internal resources to fulfill customer orders or expectations, production planning enables manufacturers to operate more intelligently. What, when, and how much to produce are all resolved by it. It determines the raw materials, bill of materials, or alternative bill of materials required to meet demand in addition to establishing production capacity. It then creates a feasible production schedule.
What is production control
6 Steps Of Production Planning And Control, Production control provides visibility and reporting while keeping an eye on output and performance. Production control is notified if any corrective action is required. It uses a variety of control strategies to reach the best possible production performance levels.
Know About bjectives of production planning and control
The following are the main goals of production planning and control:
- Optimize your resource allocation and scheduling to satisfy production demands.
- Make sure your timetable is effective.
- Be prepared with resources for when they are needed.
- Maintain ideal quantities of inventory
- Boost internal resources’ (people, work centers, equipment, tooling, etc.) productivity
- Boost client satisfaction
- Make sure the appropriate person is allocated to particular procedures.
- Work along with other departments, such as buying, customer service, and sales.
6 Steps Of Production Planning And Control, The foundation of any industrial facility is production planning and management. Among other things, it covers demand management, long-term planning, master production scheduling, and material forecasting. Forecasting a product’s demand is the first step in the planning process. The production plan is developed using the projected data and the internal resources at hand.
6 Steps Of Production Planning And Control, A method for organizing a series of activities that helps manufacturers arrive at the appropriate location and time is called production planning and control. It enables them to make the best use of their resources. Activities from other departments, such marketing, sales, and procurement, are also included.
Benefits of production planning and control
The following are just a few of the numerous advantages of production planning and control:
Optimized manufacturing capacity: – Makes sure workers and equipment are operating at maximum efficiency. This lowers expenses, boosts productivity, and boosts profitability. Planning for growth and identifying opportunities for improvement are beneficial.
Reduced inventory costs: – Enables producers to keep just the inventory that is required. The software has a Just-in-Time scheduling approach and is able to forecast demand. Costs are kept low when there is no excess inventory.
On-time deliveries:- aids in ensuring timely deliveries and production optimization. Customer satisfaction increases when products arrive at their destination on schedule. Referrals and client retention both rise as a result.
Better procurement of materials :– Indicates when to buy production-related materials. Knowing this information makes it easier to determine what is required to meet production and customer demands as well as when to place orders. Purchasing ahead of time allows procurement to obtain the cheapest price. Additionally, this enhances supplier connections and saves money.
Streamlined production processes :- Guarantees that production-related materials and internal resources are available when needed and displays the capacity and timing of availability. This maintains manufacturing efficiency. Additionally, it increases worker happiness by removing annoyance caused by disruptions in workflow and productivity.
Minimal resource waste: – Reduces resource waste by getting rid of material surpluses or shortages. Employee time wasted is reduced as a result. Unused inventory does not encumber capital. Delays that result in discarded resources are reduced, which reduces production waste.
What is the role of production planning and control in manufacturing
Production control and planning guarantee that the necessary resources are available when needed. To maximize productivity, workers, supplies, and machinery must be available as needed. It is the main component of a manufacturing company. PPC becomes increasingly necessary for a firm to run smoothly as it grows in size.
6 Steps in production planning and control
1. Planning: –
6 Steps Of Production Planning And Control, Planning establishes what, by whom, and how will be produced. It creates the production-related manpower, equipment, work areas, and material requirements plan.
A production plan can be developed with the aid of pertinent data from multiple sources. Sales data on order quantities and scheduled delivery dates, for example. The engineering department’s product specs can also be required. The planning stage aids in maintaining a production process that is efficient.
2. Routing
The factory’s raw material flow is determined by routing. The sequence is used to convert raw resources into final products.
Measuring the length of the production process requires arranging each stage and coordinating the entire operation. Routing demonstrates the amount and caliber of resources and materials required. It also displays the production location and the processes that were employed.
The “How,” “What,” “How much,” and “Where” of production are all managed via routing. For optimal outcomes, it optimizes resources and systematizes the process.
3. Scheduling
The focus of scheduling is on “when” the operation will be finished. It seeks to maximize the amount of time allotted for the operation’s completion.
According to Kimball & Kimball, scheduling is defined as
“Determining how long it should take to complete the entire series as routed, taking into account all relevant factors.”
To manage the time component, organizations employ a variety of schedule formats. Among them are the daily schedule, operation schedule, master schedule, and others.
4. Loading
Loading examines how much effort is put on workers or machines. The work previously planned for the machine or workstation is increased by the total amount of time needed to complete the new task.
Additional orders can make up the underload if a machine or workstation has capacity available. Bottlenecks can be avoided by taking proactive steps if there is a capacity excess. Possible solutions include hiring a subcontractor, adding a shift, asking for overtime, or bringing in operators from another shop.
5. Dispatching
Orders and their instructions are released through dispatching. It adheres to the scheduling and routing guidelines. This stage ensures all components are in place for the personnel to accomplish their jobs.
Here are the points that are part of “Dispatching”:
- Provide fixtures or materials that are necessary for production.
- Send out drawings or orders to start the process.
- Keep the records up to date from beginning to end.
- Launch the control process.
- Work should be cascaded from one process to another.
6. Follow-up
6 Steps Of Production Planning And Control, Follow-up, also referred to as expediting, finds errors, flaws, and production process bottlenecks. In this step, the team compares the real performance to the expected performance after measuring the actual performance from the beginning to the finish.
6 Steps Of Production Planning And Control, Problematic areas need to be addressed. Follow-up identifies the source of the problem and aids in its resolution. For example, is there a unique condition causing schedules to be missed? Or does something need to be changed? To fix the problem, the production manager might have to change the loads, timetables, or production targets.
Types of Production Planning
1. Master production schedule
A master production schedule is a plan that specifies the goods, quantities, and start times of production. A master production schedule’s objective is to develop a practical strategy that minimizes excess and guarantees on-time delivery of items.
2. Materials requirement planning
Planning for material requirements guarantees raw material availability, keeps stock levels as low as feasible, encourages inventory control, and aids in purchasing activity planning.
3. Capacity planning
The process of figuring out how much production capacity a company needs to meet customer orders and fluctuating product demand is known as capacity planning. It seeks to achieve equilibrium between supply and demand, as well as between costs and resources.
4. Workflow planning
Planning a series of actions carried out during the production process is known as workflow planning. It enables you to monitor the progress of each task and determine who is in charge of seeing it through to completion. Stated differently, workflow planning aids in monitoring the task’s progress.
Know About Production Planning Tools
6 Steps Of Production Planning And Control, Manufacturers use a variety of tools, including spreadsheets, charts, and visualization software, to create production plans and monitor their progress. To guarantee that the plant floor is operating efficiently and that deliveries are made on schedule, you can employ production control techniques and production planning with a single ERP solution rather than purchasing several solutions.
6 Steps Of Production Planning And Control, Real-time visibility provided by enterprise resource planning (ERP) software aids decision-makers in comprehending deviations, getting rid of waste, increasing output, and enhancing organizational transparency. Because it can be done on mobile devices without leaving the workstation, ERP makes it simple to update a job’s status.
Benefits of ERP in production planning
6 Steps Of Production Planning And Control, Data entry and other repetitive duties are eliminated by the automated workflow provided by modern ERP. ERP assists manufacturers with production planning, execution, and control while incorporating these functions into other corporate processes.
6 Steps Of Production Planning And Control, ERP’s built-in Material Requirement Planning feature guarantees minimal stock and reduces the risk of storing excess inventory. It guarantees streamlined and effective manufacturing procedures.
How does Opti Pro ERP help manufacturers with production planning and control
6 Steps Of Production Planning And Control, The industry-leading platform for small and medium businesses, SAP Business One, seamlessly integrates OptiProERP, a manufacturing ERP. In a single system, it offers a comprehensive view of inventory demand, plant floor data, backlogs and bottlenecks, and resource capacity.
6 Steps Of Production Planning And Control, To find out how OptiProERP can help you organize production activities to boost your productivity and profitability, get in touch with us.
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