Production Control & Logistics

Description

Logistics and material flow management have been an age-old issue in driving operational improvement. Compared with manufacturing, there are not too many tools that could be effectively used. On the other hand, there are many proven models, standards and best practices, ‘baptized by fire’, which is the topic of this part of the LEAN Academy.

A particular place in the ‘logistic challenge’ is taken by Production Control, or production planning. Nowadays, companies are faced with high variability in customer demand and are requested to be highly responsive to any changes that may happen at any time. This often causes tremendous cost to the organization. Because of this the expectations to control production resources and ensure stable production are continuously growing.

In this module we will become familiar, amongst other things with the rules of production. Levelling to secure optimum planning and utilization of manufacturing resources over a defined period. Thereafter, creating the MPS: Master Production Schedule – a short term (weeks) tactical and operating plan Followed by the S&OP: Sales & Operations Plan which is the medium-term (months) strategic plan to drive all the manufacturing resources to be used as effectively as possible.

Recommended Audience

Logistic and Production management staff, schedulers, LEAN leaders.

Methodology

Multimedia presentation, short lectures, individual exercises, group activities and discussions and Q&A

Learning Objectives

Production Control & Logistics (1 day).

• Why is understanding of the Logistics function and role so important?
• Getting to know the best practices in the field of material flow: from the inbound area, through supplying the production line, to the outbound area (TPA).
• Production line feeding system and internal transport by small train
• How Kanban system supports the overall material flow organization (incl. Sequencer / Heijunka)
• MPS and S&OP in the planning and production control strategies
• Supply management optimization, incl. “ Milk-run” instruction
• Standardization and continuous improvement of the PC&L processes.

Tools / Templates / Methods

• Sales & Operations Plan. Example of use as a typicalAn example of a template that reflects most typical approach to planning in a medium-term time horizon (6-12 months). It covers the section of volumes and calendar as well as the critical resources and income forecast which may be juxtaposed with the budget.
  This template is very helpful to level production volumes and becomes a baseline for setting the Master Production Schedule.

Price