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Effective Production Planning & MRP

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Course Outline:
This course introduces the various stages of production planning and the relationship between each stage. Participants will learn the interdependencies of each stage and the importance of considering available capacities. Appropriate strategies for everyday application will be developed including some important inventory control techniques. For example the principles and application of Just-in-Time and Kanban will be examined in detail.

The understanding and use of MRPI as a tool in planning is a core element of the course. The development of MRPI as part of MRPII and ERP will be explained and put into context. Participants will understand the benefits and pitfalls of using MRP and the degree to which it can be used in support of a manual system. Emphasis will be placed on combining theory with practical application therefore a combination of short lectures, individual & group discussions and exercises will be used

People who should attend:
This two day course is designed for those requiring a fuller understanding of the production planning process and for those requiring a basic understanding of MRP II. It may be used as a catalyst to introducing new systems or as a means of improving upon an existing system.

Course Objectives:

• Understand the stages of production planning and how they may be managed.
• Examine the negative implications of poor production planning.
• Assess the interrelationships between production planning and inventory planning.
• Explore some basic inventory management concepts and techniques.
• Understanding and be able to apply effective capacity planning techniques.
• Understand the MPS and how it ties into MRPI
• Appreciate the differences between MRPI, MRPII and ERP
• Practice capacity planning application
• Understand the concept of just-in-time
• Understand the concept and application of Kanban
• Appreciate the importance of employee involvement

Course Content:

• The Strategic Importance of Planning and Inventory Management Principles
  Objectives of Materials Management
  Effects on Capital Employed
  Stockholding Costs
  Stock Turnover
  ABC Classification
  Lead Time Definitions

• Medium to Long Term Planning
  Types of Production Systems
  Production Planning Objectives
  Consequences of Poor Planning
  Planning Horizons
  Developing the Master Production schedule (MPS)
  Strategies for Smoothing Demand

• Medium to Short Term Planning
  Materials Requirements Planning (MRPI)
  Planning Inputs and Outputs
  Capacity Planning
  The Importance of Data Accuracy
  MRPI v MRPII v ERP
  Shop Floor scheduling and Control
  The Control Process and Importance of Feedback

• Production Planning and Just-in-Time
  Internal and External Customer/Supplier Relationships
  Principles of Just-in-Time – Waste Elimination
  Kanban – Understanding and Application
  The Importance of Employee Involvement
  
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