INTRODUCTION TO

PRODUCTION PLANNING
IN AUTOMOTIVE

BY. UJANG RAHMAT (ECI – JABAR 3)

EXECUTIVE SUMMARY

1 I NTRO DUCTI O N
Supply Chain Management Model in
4 P RO CE S S F L O W
Manufacturing Process Flow Process from
Automotive Industries Part to Vehicle

P L A NNI NG & RE A L I Z ATI O N

2 P RO DUCT F L O W
Product flow from Customer Order to Delivery
5 F L O W, S TRATE G Y & ME TRI C
Flow from Sales Order to Production Order
Realization . Measurement of Process
Performance.

S K I L L S E TS F O R
3 MATE RI A L F L O W
Material flow from Supplier to Car
6 P RO DUCTI O N P L A NNE R
Some essential skill sets must have by
Manufacturing site Production Planner in Automotive

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AUTOMOTIVE SCOR MODELS

Integrated
System

Used Buy
Car Back

3
PRODUCT FLOW

CUSTOMER MAKE (CKD) /

ORDER DEALER ORDER BUY (CBU)

Costumer Walk-in or Dealer Issue PO to DB Issue PO to Plant

Event Driven Order Distributor via DLR via Sales System
System
CBU ARRIVAL
Vehicle
Order
Vehicle Hand-
over

DELIVERY
ACC. & PDI TRUCKING CUSTOMER

Accessories Install & Delivery to Dealer Delivery to Customer

Pre Delivery Inspections

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 Mining,
Petrochemical

1 Steel Melting,
Up-
Coil , Pipe
Steam
Process Stamping,
2
Supplier Welding
Tier – 2
to Tier-N
3 Door OTR
Suppler
Tier -1
Door Assy
4
Line /
Assembly
Part
5
After
M AT E R I A L F L O W
Sales
Material /Part flow from up-stream (Raw Material).
Part
Proceed by N- Supplier become line part & send to Dealer as
after sales part.

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PROCESS FLOW

Cast &
Engine & TM
Machining
Accessories
Color Plastic
Mold & Injection
Parts

Stamping

Body / Welding Assembly Trim Pre Delivery

Shop & Chassis Inspection
WELDING & ASSEMBLY OF ACCESSORIES
ASSEMBLY METAL INSTRUMENT, INSTALLATION,
PART Paint Shop ENGINE/TM, Final STANDAR TOOLS,
FINISHER Inspection MANUAL BOOK
COATING, SEALING, (PLASTICS PARTS)
COLORING
FUNCTION CHECK,
STATICS /DINAMIC
TEST, FIT & FINISH
PROD. PLANNING & REALIZATION FLOW

MKT, Sales, Product

Planning Activity to Trigger
Demand

1.Sessional Event
2. Auto-Show
3. Road-Show
4. TV Commercial
5. Community Group
6. Sponsorship
7. Face-Lift / Special version
8. Fleet / B2B Sales
9. Other Promotion

R eso u rc e P lan n in g ,M P S & R C C P

Source : APICS CSCP Module 2 : 2018
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PLANNING & CONTROL ACTIVITY

LOADING & CAPACITY

M ONITORING & PLANNING
CONTROL Determine line JPH, Working Calendar
& Working Shift by Considering OEE.
Prod Recovery Plan, Line Re-calculation of MP, WH Space,
Improvement Tools / Jig/ Pallets/ Package Numbers

M ASTER
M ODEL & COLOR
SCHEDUL ING
SEQUENCING Trigger the MRP running, Setting
Delivery Date and Delivery L/T &
Trigger Delivery time, lot size and
Safety Stock.
supply List .

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 REAL - TIM E &
INTEGRATED SYSTEM
Using proper integrated system for
speed and accurate progress control.

M ODEL & VOLUM E

L EVEL ING
Stabilize process, avoid Waste,
Muda, Mura, Muri

CF T - CONTROL F UNCTION
PRODUCTION Bridging Partners to Shop floor, Genba
based Control & Execution activity.
PLANNING &
E XE C U T I O N
QRQC
S T R AT E G Y Quick Response Quality Control to
Optimize the available resources and Minimize Speed up Problem Solving & PDCA
Cost. cycle

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KEY PERFORMANCE
Opt i mi ze Pr ocess & F aci l it y
( OEE Achi evement /Ut i l i zat ion)
Or de r Ti me F ul l f ilment
( St a nda r d Del i v. Ti me Achi evement )
Production Finish Time Achievement
Opt i mi ze Cos t & Pr od. Vol ume
(Pr o d . Ac h i e ve m e n t, OT Co st &
I n ve n to r y L e ve l )
Pr ocess st abi l i zation
( Sequence Achi evement ,
St r ai ght Run Rat i o)
Realization of Prod
Sequence
Should match with
original Schedule.
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SKILL SETS for PLANNER

1 BIZ .PROCESS KNOW LEDGE 4 PROBLEM SOLVING IDEAS

End to end Business Process Knowledge for helicopter views to Solutions oriented to get the order done by removing production
enhance collaboration within Supply Chain Element. line problem with the proper planning & scheduling.

2 PROCESS VALUE STREAM 5 DECISIONS & EXECUTIONS

Looking Into the process to find improvement area for process Draw the decisions and control the executions to catch up
optimizations. production & satisfy customers.

3 SYSTEM & DATA ANALYTICS 6 INTER- PERSONAL SKIL L

Hands on production system & data analytic .Process the Extensive CFT (cross functional team) collaboration &
information to get insight by looking into current progress and communications.
possibility in future (forecasting).

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THANK YOU!
ANY QUESTIONS?