Production Planning and Scheduling Training Course Outline

Module One: Overview of Planning and Control

  • Manufacturing versus Service Operations
  • Customer Influence in Design
  • Process Categories
  • Order Winners and Order Qualifiers
  • Business Environment Issues
  • Process Analysis and Information Flows
  • General Information Flows
  • How Technology and New Software Are Changing Manufacturing

Module Two: Forecasting Fundamentals

  • Fundamental Principles of Forecasting
  • Major Categories of Forecasts
  • Forecast Errors

Module Three: Sales and Operations Planning

  • Purpose of Sales and Operations Planning
  • General Design of Sales and Operations Planning
  • Approaches to Sales and Operations Planning
  • Strategies for S&OP
  • Qualitative Issues
  • Some Business Environment Issues

Module Four: The Master Schedule

  • Background and Links to the S&OP
  • Master Schedule Horizon
  • Time Fences
  • Sources of Demand
  • Basic Methodology
  • Impact of Product Environment
  • Available-to-Promise Logic
  • Planning Options in an ATO Environment
  • The Two-Level Master Schedule
  • Master Scheduling Responsibility
  • Demand Management
  • Overview
    Elements of Demand Management

Module Five: Inventory Management

  • Basic Concepts of Inventory
  • Categories of Inventory
  • The Basic Inventory Lot Sizing Model – Economic Order Quantity (EOQ)
  • Basic Independent Demand Inventory
  • Reorder Models
  • Inventory Control

Module Six: Material Requirements Planning and MRP II

  • Background and Fundamental Concepts
  • Bills of Material
  • The MRP Explosion
  • Other MRP Issues
  • Potential MRP Challenges
  • Enterprise Resource Planning (ERP)
  • Business Environmental Issues

Module Seven: Capacity Management

  • Capacity Definitions
  • Rough-Cut Capacity Planning
  • Capacity Requirements Planning (CRP)
  • Input/Output Control
  • Capacity Measures
  • General Approach to Capacity Management

Module Eight: Production Activity Control

  • General PAC Information and Data
  • Prioritizing Work Scheduling
  • Loading
  • Corrective Actions

Module Nine: Lean Production and JIT

  • Fundamental Concepts
  • Some Impacts on Capacity
  • The Pull System
  • Kanban
  • Using the Kanban System for Process Improvement
  • Master Scheduling and Lean Production
  • Are MRP and JIT Compatible?

Module Ten:  Theory of Constraints

  • Fundamental Principles of the Theory of Constraints
  • Understanding and Managing the Constraints
  • Improving the Process using TOC Principles
  • Impacts on Operations Strategy
  • General Types of Constraint Causes
  • Logistics and Theory of Constraints
  • Scheduling and the Theory of Constraints
  • Multiple Time Buffers
  • Control Points and Batches

Module Eleven: Partnering Activities – Purchasing and Distribution

  • Purchasing
  • Information Issues
  • Purchasing Responsibility for Material Procurement
  • Distribution Requirement Planning

Module Twelve: System Integration and Implementation

  • General System Design and Selection
  • Push, Pull, or Somewhere in Between
  • General Implementation Approaches