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Production Planning Control Practical

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Description

1. Course Outline

Module 1: Introduction to Production Planning & Control

  • Overview of Manufacturing & Production Systems
  • Importance of PPC in Operations Management
  • Key Functions of PPC: Forecasting, Scheduling, Inventory Control

Module 2: Demand Forecasting & Capacity Planning

  • Forecasting Techniques (Qualitative & Quantitative)
  • Capacity Planning & Resource Allocation
  • Case Studies on Demand Fluctuations & Capacity Utilization

Module 3: Master Production Scheduling (MPS)

  • Developing a Master Production Schedule
  • Practical Workshop: Creating MPS using Software (Excel/ERP)
  • Load Balancing & Scheduling Strategies

Module 4: Material Requirement Planning (MRP) & Bill of Materials (BOM)

  • Fundamentals of MRP & BOM Structuring
  • Hands-on: Preparing BOM & Running MRP Scenarios
  • Case Study: Optimizing MRP for Cost Reduction

Module 5: Inventory Management & Control

  • Types of Inventory & Control Techniques (EOQ, JIT, ABC Analysis)
  • Practical Application: Inventory Tracking & Reorder Point Calculation
  • Reducing Waste & Improving Turnover Rates

Module 6: Scheduling & Shop Floor Control

  • Production Scheduling Methods (Gantt Charts, Line Balancing)
  • Shop Floor Data Collection & Process Optimization
  • Live Case Study: Scheduling in a Real-time Manufacturing Setup

Module 7: Lean Manufacturing & Continuous Improvement

  • Introduction to Lean, Six Sigma, and Kaizen
  • Practical Exercise: Identifying Waste & Implementing Lean Tools
  • Real-world Applications of Continuous Improvement in PPC

Module 8: ERP Systems & Digital PPC Tools

  • Introduction to ERP Systems (SAP, Oracle, MS Dynamics)
  • Practical Session: Hands-on Training with PPC Software
  • Case Study: Implementing PPC in an Automated Environment

Module 9: Performance Measurement & KPI Tracking

  • Key Performance Indicators (KPIs) in PPC
  • Workshop: Setting Up and Monitoring KPIs in a Manufacturing Setup
  • Data-driven Decision Making for Continuous Improvement

Module 10: Final Project & Assessment

  • Real-world Industry Case Study
  • Team-Based Practical Project on PPC Implementation
  • Final Review & Certification

2. Course Objectives

By the end of this training, participants will:

  • Gain a comprehensive understanding of Production Planning & Control principles.
  • Learn how to forecast demand and plan production schedules efficiently.
  • Apply MRP and inventory control techniques to optimize resources.
  • Develop proficiency in using PPC software and ERP tools.
  • Implement lean and continuous improvement strategies in production.
  • Analyze and improve production performance using KPIs.

3. Learning Outcomes

Upon successful completion of the course, learners will be able to:

  • Develop and manage an effective production plan.
  • Utilize MRP and scheduling techniques to optimize manufacturing processes.
  • Apply lean principles to reduce waste and enhance efficiency.
  • Use ERP systems for PPC execution in a real-time environment.
  • Monitor production KPIs and suggest improvements.
  • Solve real-world PPC challenges with data-driven decision-making.

4. Training Methodology

This course follows a practical, hands-on approach to ensure maximum retention and application of knowledge.

  • Instructor-led Sessions: Concept explanations with real-life case studies.
  • Hands-on Workshops: Practical exercises using Excel, ERP, and PPC software.
  • Case Studies: Analysis of real-world PPC scenarios.
  • Group Discussions & Problem-Solving: Collaborative learning approach.
  • Industry Expert Talks: Insights from manufacturing professionals.
  • Simulations & Live Projects: Realistic PPC implementation exercises.
  • Assessments & Certification: Periodic evaluations through quizzes, practical tasks, and a final project.

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