Production Management and Material Requirements Planning

In today's fast-paced business landscape, the efficient management of production and operations is crucial for the success of any organization. At IIPD Global, we recognize the significance of this facet of business and are committed to providing you with a comprehensive understanding of production and operations management.

In a dynamic business environment, accurate time estimates are invaluable. Our course delves into the concept of probabilistic time estimates, teaching you how to make reliable predictions in situations where outcomes are uncertain. This knowledge will assist you in realistic project planning and resource allocation.

Course Duration5 Days

Course objective:

This course enables the participants to:

  • Understand the definition of Planning and identify the types of Planning.
  • Understand the different levels of operational planning
  • Understand the relationship between planning and budgeting.
  • Understand the concepts of integral quality management and benchmarking in their different aspects.
  • Understand the strategic capacity management concept
  • Understand the Sales and Operations Aggregate Planning process
  • Understand the Material Requirements Planning method

Who should attend?

This course is concerned with the techniques to improve firms’ ways of production operation planning and how to use some instruments such as ratios and metrics to control it. Hence this course targets mostly managers, supervisors, and team leaders in all vocational operation areas within the organization.

Module "1" – Importance of Strategic Planning

  • Operations Strategy
  • Definitions and practical implications
  • Levels of Strategy in Organizations
  • Strategy alignment with Operations
  • Investment in Manufacturing strategy
  • Functional strategy
  • Manufacturing Fundamental Concepts
  • Tradeoffs
  • Economies of Scale
  • Differentiation
  • Mixed strategy
  • Postponement
  • Standardization
  • Economies of Scope

Module "2" Production Strategies and Configurations

  • Product Classification
  • Effect of Consumer Goods on Production
  • Effect of Product Life Cycle on Production Planning
  • Manufacturing Operations Strategies
  • De-Coupling Point
  • Production strategies decision making
  • Push and Pull Planning systems
  • MRP
  • JIT
  • Kanban

Module "3" Process Strategies and Configurations

  • Production systems
  • Continuous flow
  • Discrete flow
  • Process systems
  • Intermittent
  • Repetitive
  • Continuous
  • The Product-Process Matrix (PPM)
  • Basic factory layouts

Module "4" Strategic Capacity Planning

  • Importance of capacity planning decisions
  • Determinants of effective capacity
  • Key decisions in production capacity planning
  • Tradeoffs between make or outsourcing
  • Vertical and Horizontal integration
  • Determining capacity bottlenecks and required investments

Module "5" Production Planning and Control of Resources

  • Assembly Line Balancing
  • Assembly Line Balancing Equations
  • Ranked Positional Weight Heuristic
  • Job Shop Scheduling
  • Scheduling multi-tasks on One station
  • Scheduling multi-tasks on Two stations
  • Scheduling multi-tasks on Multi stations

Module "6" Production Planning methods and techniques

  • Economical Production Quantity
  • Identifying variables
  • Building economical model
  • Minimizing total cost
  • MRPII (Manufacturing Resources Planning)
  • The integrated functional model
  • BOM (Bill of Material)
  • Importance of Modular BOM and Super BOM
  • RCCP (Rough Cut Capacity Planning)
  • ERP vs MRPII and ERPII evolution 

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