Production Planning Control Practical

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.