Perencanaan Dan Pengendalian Produksi.w_p1_Production Planning_Introduction

7/23/2019 Perencanaan Dan Pengendalian Produksi.w_p1_Production Planning_Introduction

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Saroyo_PPIC__1

Production PlanningProduction Planning

andandInventory ControlInventory Control

Lecture by

Pujo Saroyo



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Production Planning & ControlProduction Planning & Control

Information SystemsInformation Systems

Demand Forecasting

Long-range Capacity

Planning

Inventory Monitoring

and Control

Short-range

requirements

Planning

Shop Schedulling,

Monitoring and

Control

Sales and Order

ntryCustomer

Production

Inventory

Shiping and

!eceiving

"endors

Production Planning and Control Systems



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Long-range capacity planning#

!esource planning $gregate planning

!ough-cut capacity planning Master Production scheduling

Detailed capacity planning Detailed materials planning

Operational Planning

Shop schedulling, Monitoring and control#

D

e

m

a

n

d

M

a

n

a

g

e

m

e

n

t

%ime

Production planning



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Production Planning &ori'onsProduction Planning &ori'ons

Master Production SchedulingMaster Production Scheduling

Production Planning and Control SystemsProduction Planning and Control Systems

Pond DrainingPond Draining

SystemsSystems

Aggregate PlanningAggregate Planning

PushPush

SystemsSystems

PullPull

SystemsSystems

Focusing onFocusing on

ottlenec!sottlenec!s

Long-"ange Ca#acity PlanningLong-"ange Ca#acity Planning Long-RangeLong-Range$years%$years%

Medium-RangeMedium-Range

$&-'( months%$&-'( months%

Short-RangeShort-Range

$)ee!s%$)ee!s%

Very-Short-RangeVery-Short-Range

$hours - days%$hours - days%



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Production Planning( )nits o* MeasureProduction Planning( )nits o* Measure

Master Production SchedulingMaster Production Scheduling

Production Planning and Control SystemsProduction Planning and Control Systems

Pond DrainingPond Draining

SystemsSystems

Aggregate PlanningAggregate Planning

PushPush

SystemsSystems

PullPull

SystemsSystems

Focusing onFocusing on

ottlenec!sottlenec!s

Long-"ange Ca#acity PlanningLong-"ange Ca#acity Planning EntireEntireProduct LineProduct Line

ProductProduct

FamilyFamily

SpecificSpecific

Product ModelProduct Model

Laor! Material"!Laor! Material"!

Machine"Machine"



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&ierarchical Production Planning&ierarchical Production Planning

Annual demand by

item and by region

Monthly demand

+or '* months by

#roduct ty#e

Monthly demand

+or * months by

item

Foreca"t" needed

Allocates

#roduction

among #lants

Determines

seasonal #lan by

#roduct ty#e

Determines monthly

item #roduction

schedules

#eci"ion Proce""#eci"ion Le$el

Cor#orate

Plant manager

Sho#

su#erintendent



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Production Control requires(Production Control requires(

Aailable in+ormation about #roduction

o#eration in a timely +ashion

Data collected +rom all segments o+

#roduction. receiing/ shi##ing/

)arehousing/ manu+acturing/ maintenance/

and so on



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The primary inputs needed fromThe primary inputs needed from

the shop floor:the shop floor: '0 "esource status $#eo#le/ machine/ tools/ ins#ection

e1ui#ment/ material handling e1ui#ment%

A0 )hat resources eist

0 heir o#erating status

C0 their limitation and ca#abilities

20 5ob Status.

A0 6or! order actie in the schedule 0 7#erations that corres#ond to that orders

C0 he com#letion status o+ each order



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30 Material status. A0 6hich #arts are in the #lant

0 9umber o+ #arts in inentory

C0 9umber o+ #arts allocated to actie )or! order

D0 9umber o+ #arts on order/ and )hen deliery ise#ected

40 Schedule Status $+or each scheduled resource%.

A0 7#erations scheduled

0 :#ected #rocessing time o+ each o#eration

C0 otal scheduled #rocessing time

D0 Present se1uence o+ o#erations

:0 :#ected com#letion time



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*0 Material moe status.

A0 Moe tic!ets #resently actie

0 any tic!ets +or urgent items

&0 "ecent #er+ormance status.

A0 Percentage o+ resources used

0 Aerage time in system +or jobs

C0 Present alue o+ eisting inentory

D0 Aerage ratio o+ o#eration run oer standard runtime +or o#erations

:0 Percentage o+ items scra##ed at ins#ection

F0 Aerage time to com#lete a material moe

<0 For all the #receding items/ any resources/ jobs/ #arts and so on that #er+ormed out o+ acce#table limits



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Production Control In*ormationProduction Control In*ormation

Outputs(Outputs("e1uirement #lanning re#orts.

A0 Product demand +orecasts

0 6or!e +orce and #roduction #lan C0 Finished #roduct assembly #lan $master schedule%

D0 Parts #roduction re1uirement #lan

:0 Projected )or! center load re#ort

F0 =endor #arts deliery #lan

<0 Shi##ing doc! #lan

>0 ill o+ material



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?nentory Control re#orts.

A0 Stoc! status 0 ?tems on order

C0 Critical items ece#tion

7#erations scheduling re#orts

A0 6or! schedule

0 6or! order authorisation

C0 6or! orders location and status

D0 Production #rocess routings :0 "e)or! orders

F0 Maintenance )or! order



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Material handling re#orts.

A0 6or! moe tic!ets

0 Stoc! location

C0 Parts receiing

D0 Product shi##ing @uality control re#orts.

A0 ?ns#ection )or! order

0 Scra# re#orts

C0 @uality control trend analysis



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Assembly re#orts.

A0 Asembly schedule 0 Assembly #rocedure routings

C0 Stoc! locations

Sho# +loor control re#orts

A0 labour e++iciency

0 Missing stoc!

C0 machine utilisation

D0 Absenteeism analysis



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Production planning and controlProduction planning and controlContent"% Introduction% &$er$ie' of Production planning #emand Foreca"ting %

Mo$ing a$erage! e(ponential "moothing! linear regre""ion! non linear regre""ion! and "o

on )ggregate Planning Ma"ter Production Schedule Capacity Re*uirement Planning Material Re*uirement Planning In$entory analy"i" and control%

)+C "y"tem

E&, model" In$entory 'ith Safety "toc In$entory 'ith "hortage con"ideration

Scheduling 'ith re"ource con"traint" Re"ource alancing Line alancing

.o Se*uencing and "cheduling Per"onnel Scheduling

Referene"% +ed'orth! #a$id! Integrated Production Control Sy"tem"!.ohn 'iley and Son" /oori! 0amid Ru""el Radford! Production &peration" management! MC 2ra' 0ill

Company! International Edition3 El"ayed! El"ayed! )naly"i" and Control of Production Sy"tem" Ste$en"on! 4illiam! &peration" management! 5665! MC 2ra' 0ill Company! International

Edition! Se$en Edition3

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Perencanaan Dan Pengendalian Produksi.w_p1_Production Planning_Introduction