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.