BASIC PRODUCTION DATA

Rajiv Misra
 EVOLUTION OF PPC SYSTEMS

EXPEDITING

ORDER POINT 1 KG/DAY

GAS 14 LT
TECHNIQUES 2d
2

MRP-I

JIT (PULL) MRP-II (PUSH) TOC

Present
ERP

Future
ERP + SCMS+PDM+HRM+APS PRESCRIPTIVE?
Rajiv Misra
PUSH, PULL AND TOC

Rajiv Misra
 HOW DOES PUSH WORK ?

Week 5 Week 6 Week 7 Week 8 Week 9

50 Parts
Due Date
Week 10

Release 50
parts on
Week 6!
Release 50
parts on
Week 5!

Rajiv Misra
 HOW DOES PUSH WORK ?

Week 5 Week 6 Week 7 Week 8 Week 9

50 Parts
Due Date
Week 10

Release 50
parts on
Release 50 Week 6!
parts on
Week 5!

MATERIAL

INFORMATION
Rajiv Misra
 HOW DOES PULL WORK ?

Due Date
Week 10
1 2 3 C

4 5 6 7 8

Rajiv Misra
 HOW DOES PULL WORK ?

Due Date
Week 10
1 2 3 C

B A

4 5 6 7 8
For Example, a Demand of Two Greens

MATERIAL

INFORMATION
Rajiv Misra
 HOW DOES TOC WORK ?

Drum Buffer Rope

Step 1: Identify The Constraint

RM 1 2 3
Demand:
60 80 70
8 50 Units
Per
95
RM 4 5 6 7 Week
80 75 50 120
 HOW DOES TOC WORK ?

Step 3: Subordinate Everything to The Constraint Drum Buffer Rope

RM 1 2 3
Demand:
60 80 70
8 50 Units
Per
95
RM 4 5 D 7 Week
80 75 TIME 50 120
BUFFER
WORK FLOW IN AN ETO INDUSTRY

Rajiv Misra
OVERVIEW OF MANUFACTURING PLANNING

MASTER Derived from

PRODUCTION Aggregate Plans,
Forecasts, Orders
SCHEDULE (MPS)
WHAT WE PLAN
WHAT
WHAT WE
BILL OF WE
REQUIRE MRP HAVE
MATERIAL INVENTORY
CRP
(BOM)

WHAT WE NEED

PURCHASING MANUFACTURING
Rajiv Misra
 MASTER PRODUCTION SCHEDULE

¾ FORMAL STATEMENT OF WHAT WE TO MAKE WHEN

¾ DEPENDENT ON THE TYPE OF THE INDUSTRY- ETO/MTS

¾ SHOULD NOT BE A WISH-LIST

¾ TECHNICAL TECHNIQUES
¾ ROUGH CUT CAPACITY PLANS

¾ ADMINISTRATIVE TECHNIQUES: TIME FENCES

RATE FENCE MIX FENCE FIRM FENCE
PARTY
3 PM 6 PM 7 PM AT
8
CANNOT CHANGE NO OF GUESTS CANNOT CHANGE GET LOST
VEG/NV Rajiv Misra
 BILL OF MATERIAL (BOM)

PRODUCT DEFINITION LEVEL

Parent 0
A
Child 1
B C D

End Item 2
C

EXPLOSION VS IMPLOSION

LOW LEVEL CODING

Rajiv Misra
 BILL OF MATERIAL (BOM)

BOM MUST SPECIFY THE COMPOSITION

AND
ALSO THE PROCESS STAGES OF A PRODUCT

“ Designers create BOM so that someone else can make the product.
BOM, therefore, is made for others in the first place. And it would
seem to follow that it should be structured for the user’s, not the
designer's convenience “

George W Plossl, IBM

Rajiv Misra
BOM NOT REFLECTING PROCESS: EXAMPLE

Motor Frame

Plates Motor

10 Cut Plates

20 Weld Plates

30 Machine

40 Assemble

Rajiv Misra
BOM NOT REFLECTING PROCESS: EXAMPLE

Let’s make a BOM for a DOSA

Rajiv Misra
ENTERPRISE PRODUCT DATA MGT (EPDM)

1.0 PRODUCTS LIKE METAPHASE, WINDCHILL. THEY

AROSE OUT OF THE “RELATIVE CHOAS” CAUSED
BY CAD/CAM

2.0 PRODUCTIVITY GAINS WERE UNDONE BY THE GLUT

UNCONTROLLED INFORMATION IT ENGENDERED.

3.0 INITIAL PDMs WERE ‘CAD CENTRIC’ – ELECTRONIC

VAULTS
AREAS LIKE- PRODUCT CONFIGURATION, DATA AS
IT CHANGED BETWEEN ‘AS DESIGNED’, ‘AS MADE’
NOT ADDRESSED.
HENCE THE NEED FOR EPDM

Rajiv Misra
PROCESS PLANS

Rajiv Misra
 COMPUTER AIDED PROCESS PLNG (CAPP)

1.0 PROCESS PLANNING: MANUFACTURING

INSTRUCTIONS
¾ UNIQUE
¾ DIFFICULTY- SEQUENCING

2.0 APPROACHES
¾ VARIANT: RETRIEVAL / GROUP TECHNOLOGY
¾ GENERATIVE: AI APPROACH
¾ SEMI-GENERATIVE” HYBRID

3.0 OTHER ISSUES

¾ FORWARD VERSUS BACKWARD PLANNING
¾ CAD STANDARDS (IGES, STEP ETC)

Rajiv Misra
 COMPUTER AIDED PROCESS PLNG (CAPP)

1.0 PROCESS PLANNING: MANUFACTURING

INSTRUCTIONS
¾ UNIQUE
¾ DIFFICULTY- SEQUENCING

2.0 APPROACHES
¾ VARIANT: RETRIEVAL / GROUP TECHNOLOGY
¾ GENERATIVE: AI APPROACH
¾ SEMI-GENERATIVE” HYBRID

3.0 OTHER ISSUES

¾ FORWARD VERSUS BACKWARD PLANNING
¾ CAD STANDARDS (IGES, STEP ETC)

Rajiv Misra
 NETTING

CORRECT COMPUTATION
Quantity of Trucks to be made: 100
Transmissions Required (GROSS): 100
Transmissions in Inventory: 2

Net Reqmt,Transmissions: 98
Gear Boxes Reqd for 98 Trans. (GROSS): 98
Gear Boxes in Inventory: 15

Net Requirement, Gear Boxes: 83

Gears Reqd for 83 Gear Boxes (GROSS): 83
Gears in Inventory: 7

Net Requirement of Gears: 76

Rajiv Misra