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Sustainable Manufacturing and Factory Planning Production Planning and Control (PPC ) I 12.04.2017 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl © IWF TU Berlin Page 1 Table of Contents  Introduction  Production Systems  Tasks and Dilemma of PPC  Solution Approaches for PPC  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 2 Introduction Flow of material and information in PPC Purchase Orders Production Planning and Control (PPC) Customer Orders Production Order / Job Customer Supplier Raw Material, Semi-finished Products, Assemblies, Components Products Production System Material Flow Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Information Flow Page 3 Introduction Complex Framework for PPC  Different areas of a company with different goals influence the PPC purchase  Many objectives have to be considered assembly controlling PPC human resource management manufacturing marketing Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 4 Introduction Planning Levels for PPC – objective-related  The network can be interpreted as Planning Levels Network production units linked by material and information flows along the supply chain  A factory in the PPC case describes a production unit with more than one product segment and serves as a node of a supply chain network Factory  Departments are segments in which whole products are typically produced ready to ship Departments  A system in the PPC case is understood as a System group of more or less automatically interlinked cells. Cell  Often several resources are arranged into cells that typically perform most of the necessary operations to finish a work piece or an assembly including quality assurance Workstation Process Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl E.g. Milling  The main concern on the level above the processes is about the single workstations and their value adding operations including work piece and tool handling Source: [Wei-10], [Wie-07], [Wie-09] Page 5 Introduction Main components of PPC  Planning Production program planning Which product? When? Where? Quantity planning How many? Time scheduling When? How long? During which time? Which delivery date? Capacity planning Where? Which machine tool/equipment?  Often centralized responsibility by a planning department  Control  Often decentralized responsibility by the staff on site Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Order release Sequence planning Progress control Page 6 Y-cim-model business process chain technical process chain planning level Production Program Planning Product Draft Material Requirement Planning Work Planning Order Release Production Control manufacturing level CAD Product Design Capacity Requirements Planning Shop Floor Control Control of NC-,CNC-, DNC-, machines Production Data Aquisition Control of transportation systems Target-Actual Comparision (quantities, times, costs) CAE CAP CAM Control of robots and assembly PPC Quality Control CAQ CAE Y-cim-model CIM Computer integrated manufacturing CAE Computer aided engineering CAD Computer aided design CAP Computer aided planning CAM Computer aided manufacturing Computer aided quality CAQ PPC Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Production planning and control Source: [Sch-97] Page 7 Introduction Functions of PPC  Production planning and control determines  When to make available work orders, the required material, consumables, equipment and manpower  How to realize the allocation of work in time to the different work groups and workplaces  How to utilize limited resources effectively  How to manage the material flow through these resources  Which product to which amount and in which period should be produced Manpower Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Time Material www.hsteel.cn Equipment www.cnet.de www.dmg.de  How to deal with rework and rejection of course to be avoided by all means manpower Page 8 Introduction Inventory Strategies for PPC Supplier Customer make-to-stock production assembly-toorder make-to-order production customized nonrepetitive production Source Manufacturing Assembly Deliver Strategy Value Creation Customized Storage point Customer decoupling point Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Löd-13] Page 9 Introduction Objectives of PPC I Costs Quality make-to-order-production: delivery time delivery date deviation delivery reliability Flexibility Production Cost & Logistic Costs/ Flexibility price make-to-stock-production: service level Internal External Production Performance & Logistic Performance Time Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl throughput time due date deviation due date reliability inventory utilization cost of delays Source: [Löd-13]Page 10 Introduction Objectives of PPC I Costs Quality Time Flexibility  Low costs  Reducing costs in supporting processes of administration  Reducing costs in the value creation process (material, staff, product, process, equipment)  Reducing inventory in stocks and shop floor  High quality  In products, equipment, decisions and high precision in planning  Short time  Decreased processing-, throughput-, waiting-, transport-, and delivery time in the material flow, high delivery reliability  Meet due dates  High flexibility  Resource utilization  Reacting on unforeseen events  High availability (material, machine, staff) and high service level orientation Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 11 Table of Contents  Introduction  Production Systems  Tasks and Dilemma of PPC  Solution Approaches for PPC  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 12 Production Systems Toyota Production System Toyota Production System (1980s) - TPS Toyota Production System Just in time Autonomation Flexible production Total quality control Elimination of waste Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Ohn-88] Page 13 Production Systems Lean Production System – Ganzheitliches Produktionssystem I Lean Production System – Ganzheitliches Produktionssystem (State of the Art) Objectives  Improve quality  Sustained process mastery in manufacturing Value Creation Processes Principles Methods and Tools Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  Manufacturing process including selected process steps  Zero defects principle  Method: Statistical process control  Tool: Quality control card Source: [VDI-2870] Page 14 Production Systems Lean Production System – Ganzheitliches Produktionssystem II Lean Production System – Ganzheitliches Produktionssystem (State of the Art)  Principles  Standardization  Zero defects principle  Flow principle  Pull principle  Continuous improvements process  Employee orientation and management by objectives  Avoidance of waste  Visual management  VDI 2870 provides a detailed overview Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [VDI-2870] Page 15 Production System Example: Methods-Catalogue of “Siemens Production System” Action area Lean production & Value stream improvement Reliable & Zero defect processes Method  Reduction of setup time  Lean manufacturing  Total productive maintenance  Value stream analysis / design  Poka yoke  Six sigma tools  FMEA Action area Method Organization and tidiness as discipline 5S Methodology (sort, set in order, sweep clean, standardize, sustain) Proactive change management & communication Lean-thinking training Consumption driven Production  Pull-principle  Production leveling Systemic target agreements Target agreement process Transparency Visualization in the work environment Continuous improvement of value adding Continuous improvement workshop Overall lean administration Lean manufacturing support  FMEA: Failure Mode and Effects Analysis Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: siemens.com Page 16 Example: 5S Methodology sort set in order sweep clean standardize sustain Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 17 Production System Example: Lean Production System – KPI Chart  OEE: Overall Equipment Effectiveness  NRFT: Not right first time  KPI: Key Performance Indicator Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [VDI-2870] Page 18 Table of Contents  Introduction  Production Systems  Tasks and Dilemma of PPC  Solution Approaches for PPC  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 19 Strategic Planning Level Demand Planning Demand Planning Determination according to origin and product level Determination with consideration of stock Primary demand: Dependent demand: Tertiary demand: Gross demand: Net demand: Demand of salable products Demand of raw materials, parts, components for assembly of primary demand Demand of operating supply items Period-oriented primary, dependent or tertiary demand Gross demand minus available stock Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Pfo-10] Page 20
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