Effective Manufacturing Planning, Scheduling, and Control

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Course Overview

Learn how to achieve stable production schedules in conjunction with high as-promised delivery performance using demand and operations planning and a structured methodology to share and reconciled planning information. Elements and examples of MRP, high-level MRP and pull systems (kanban, yamazumi, synchronous flow boards) will be explained.

Who Should Attend?

  • Directors of production planning and inventory management
  • Plant managers
  • Value stream leaders
  • Master production scheduler
  • Production managers
  • Continuous improvement leaders

Course Outline

Day 1

Business Planning

  • 3-5 Year Plans (Strategy Deployment)
  • Annual Operating Plans
  • Monthly Planning (SIOP)

 Demand (aka Sales) Planning

  • Static Demand
  • Forecasting Models
  • Mix/Volume Considerations
  • Booking Review Meeting

 Operations (aka Supply or Production) Planning

  • Balancing Capacity, Lead time, and Inventory
  • Lot Size vs. Carrying Cost Exercise
  • Planning for Future Increases / Decreases in Demand
  • Make-To-Stock vs. Make-To-Order
  • Capacity Planning

Sales, Inventory and Operations Planning (SIOP)

  • Participants’ Roles
  • Meeting Agendas
  • Top Questions to Answer
  • Information and Templates
  • Timeline for Success

Master Production Scheduling

  • Operations Plan vs MPS
  • Strategies for Different Environments
  • Family and PFEP (Plan for Every Part)
  • Key Decision Considerations

Materials Requirements Planning (MRP)

  • MRP Structure
  • Inputs to MRP
  • Outputs of MRP
  • Overview of MRP II and EPR
  • First Time Order vs Repeat Order

 

Day 2

Understanding Inventory

  • Purpose of Inventory
  • Five Uses of Inventory
  • Inventory Costs
  • Inventory Strategies

Capacity Planning and Scheduling

  • Capacity Planning Levels
  • Capacity Requirement Planning Inputs
  • Resources Planning
  • Balancing Capacity and Load
  • Scheduling Techniques

Mainframe vs Visual Systems

  • Transaction Elimination
  • Backflushing
  • Utilizing Spreadsheets
  • Valuing Inventory

Calculating Kanban Quantities

  • Steady Demand
  • Variable Demand

 

Day 3

Visual Workplace Tools for Production Management

  • Yamazumi
  • Material Presentation Squares
  • Shop Order Priority Board
  • Synchronous Flow Board

Shop Floor Daily Communication Meetings

  • Elements for Daily Communications Meeting
  • Standard Work for Managers

Review and Course Evaluation

Instructors

Mark Carpenter

Mark Carpenter was the Division Controller at Parker Hannifin Corporation’s Quick Coupling Division located in Minneapolis, MN for 24 years prior to retiring in January 2015. Mark led the efforts of implementing Lean Accounting, Sales and Operations Planning and Strategy Deployment within the Quick Coupling Division while the division experienced 400% growth in sales. In addition to his Division Controller responsibilities, Mark taught Lean Accounting, Sales and Operations Planning and Finance for Non-Financial Managers in multiple US and worldwide Parker locations.

Jeff Oelke

Jeff Oelke oversees the Maintenance and Reliability Certificate offered through the University of Wisconsin–Madison Engineering Professional Development. Mr. Oelke has over 20 years of experience working with manufacturing companies. In addition to a thorough understanding of Lean, Six Sigma, Theory of Constraints and Quick Response Manufacturing strategies, Mr. Oelke has firsthand experience with assembly, metal forming, welding, plastics, printed circuit layout and fabrication, paint and wood products manufacturing processes. Prior to joining Engineering Professional Development, Mr. Oelke was the managing member of the Continuum Management Group, LLC, Richland Center, WI, and the division manager for supplier development at Deere and Company’s Commercial and Consumer Equipment Division. Mr. Oelke possesses MS and BS degrees with concentrations in manufacturing operations and computer hardware architecture.  He has been certified as a Six Sigma Black Belt by the American Society for Quality (ASQ).

Upcoming dates (0)

Take this course when it’s offered next!

Program Director

Jeff Oelke

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