PRODUCTION PLANNING AND CONTROL--UNIT IV PRODUCTION SCHEDULING
- 2. MATERIAL REQUIRMENTS PLANNING (MRP) MATERIAL REQUIRMENTS PLANNING (MRP) It converts master schedule in to a final product It converts master schedule in to a final product INFORMATION NEEDED FOR MRP: INFORMATION NEEDED FOR MRP: 1. 1. Demand for all products Demand for all products 2. 2. Items for finished goods Items for finished goods 3. 3. Safety stock requirements Safety stock requirements INPUTS TO MRP: INPUTS TO MRP: 1. 1. Master production schedule Master production schedule 2. 2. Bill of materials file Bill of materials file 3. 3. Inventory record file Inventory record file
- 4. 1. 1. MASTER PRODUCTION SCHEDULE MASTER PRODUCTION SCHEDULE 1. 1. Sale or distribution during specific period Sale or distribution during specific period INPUTS TO MPS: INPUTS TO MPS: Market requirements Market requirements Production plan to aggregate planning Production plan to aggregate planning Resources available Resources available BILL OF MATERIALS: BILL OF MATERIALS: How many, each of them used. How many, each of them used. INVENTORY RECORD FILE: INVENTORY RECORD FILE: Item master data segment Item master data segment Inventory status Inventory status Subsidiary data segment Subsidiary data segment
- 5. BENEFITS OF MRP BENEFITS OF MRP Reduce inventory levels Reduce inventory levels Reduce production lead time Reduce production lead time Improve product quality Improve product quality Better production schedule Better production schedule Better machine utilisation Better machine utilisation
- 6. DISPATCHING AND DISPATCHING AND EXPEDITING EXPEDITING DISPATCHING DISPATCHING Setting productive activities in motion Setting productive activities in motion Accordingly with previous planned time and Accordingly with previous planned time and sequence sequence
- 7. DISPATCHING ACTIVITIES DISPATCHING ACTIVITIES 1. 1. Movement of material from store Movement of material from store 2. 2. Issue of tool orders Issue of tool orders 3. 3. Issue of job orders Issue of job orders 4. 4. Issue of time tickets Issue of time tickets 5. 5. Issue of inspection orders Issue of inspection orders 6. 6. Issue of move orders Issue of move orders
- 8. COMMON FORMS USED IN COMMON FORMS USED IN DISPATCHING (8mark) DISPATCHING (8mark) 1. 1. Material requisitions Material requisitions 1. 1. Issuing material from store Issuing material from store 2. 2. No material issue without written requisitions No material issue without written requisitions 2. 2. Job cards/ tickets Job cards/ tickets 1. 1. Worker identity for a material Worker identity for a material 2. 2. Recording the production progress Recording the production progress 3. 3. Labour cards / tickets Labour cards / tickets 1. 1. It is knows as wage payment cards It is knows as wage payment cards 2. 2. Usually job and labour cards are combines Usually job and labour cards are combines
- 9. 4. 4. Move cards/ tickets Move cards/ tickets 1. 1. Movement of material between operations Movement of material between operations 5. 5. Inspection cards / tickets Inspection cards / tickets 1. 1. Report the quantity of work passed / rejected Report the quantity of work passed / rejected 6. 6. Tool and gauge tickets Tool and gauge tickets 1. 1. To issue any tool under requirements To issue any tool under requirements
- 10. DISPATCHING RULES DISPATCHING RULES 1. 1. FCFS (First Come First Serve) FCFS (First Come First Serve) 2. 2. SOT (Shortest Operation Time) SOT (Shortest Operation Time) 3. 3. Earliest due dates Earliest due dates 4. 4. STR (Slack Time Remaining) STR (Slack Time Remaining) 5. 5. STR/OR (Slack Time Remaining per Operation) STR/OR (Slack Time Remaining per Operation) 6. 6. CR (Critical Ratio) CR (Critical Ratio) 7. 7. QR (Queue ratio) QR (Queue ratio)
- 11. EXPEDITING EXPEDITING (PROGRESSING) (PROGRESSING) Expediting: Expediting: Also known as follow – up or progressing Also known as follow – up or progressing Plan till job is completed Plan till job is completed FUNCTIONS OF EXPEDITING: FUNCTIONS OF EXPEDITING: Status reporting Status reporting Attending holds-ups Attending holds-ups Modifying the production plans Modifying the production plans Co-ordinating with purchase Co-ordinating with purchase