INFORME EJECUTIVO

PROJECT : Envases de Colombia production plan

INTRODUCTION
Applying the knowledge learned from the concepts seen in the subject of production management, we
carried out analysis of forecasts, capacity and master plan of materials of the company envases de
Colombia SA, where we began with a detailed process of preparing sales forecasts, to project future
sales for the year 2020 based on historical data. This forecasting application not only allows us to plan
but also helps to strengthen our knowledge for the efficient administration and control of budgets,
ensuring the optimal use of resources. With the master program applied in the company in the first half
of the year mentioned above, it ensures a more efficient use of the resources used in this period. With
the master program applied in the company in the first two months of the year mentioned above, it
ensures a more efficient use of the resources used in this period.
Objective: To perform an analysis of sales behavior on an individual and aggregate basis, using
advanced quantitative models to identify and address bottlenecks in production capacity to optimize
performance, thus allowing accurate projections and informed strategic decisions to improve the
efficiency and overall performance of the sales and production process.

Project Progress Status

The behavior of the sales of Envases de Colombia Sas was analyzed, both individually and in aggregate,
several forecasting methods were used, such as the simplistic, simple average and simple moving
average, to the most advanced such as the weighted moving average, simple exponential smoothing,
linear regression, seasonality and mixed. Each was assessed with prognostic error and the results
revealed that the mixed method was better, with a 58% chance of success.

It is important to note that, during the analysis, we worked with three packaging references, specifically
1 gallon, 1/2 gallon and 1/4 gallon, to facilitate comparison, all references were converted to a single
unit, this being 1/4 of a gallon.

Capacity Analysis based on Aggregate Mixed Forecast

Based on the aggregate mixed forecast, the capacity analysis was carried out, in which information such
as the work center, time, standard time in minutes, gallon unit, human resources, machines, and minutes
per unit conversion were considered, as detailed in the following image.
1/4 CONVERSION
UNIT OF HUMAN
WORK TIME STANDARD GALLON MACHINE TO
MEASUREMENT RESOURCES
CENTER TIME (min) UND MIN/UNIDAD
IMPRESSIO
1 MIN/LAMINA 16
N UNIDAD/LAMINA 1 1 0,0625
3 MIN/CORTE
COURT 16 UNIDAD/CORTE 1 1 0,1875
1,5 MIN/GOLPE
PUNCHING 4 UNIDAD/CORTE 1 1 0,375
MIN
0,5 3
FINISHING /UNIDAD UNIDAD/MIN 3 5 0,5

During the detailed analysis of each work center, the Unit Manufacturing Time (TFU) was calculated in
minutes, along with the expected output. This made it possible to identify that the bottleneck is in the
finishing work center.
Key variables were taken into account for this analysis, covering the first half of 2020. These variables
include monthly demand, available days per month, theoretical capacity, effective capacity, Sundays and
holidays, missed and scheduled hours, actual capacity, efficiency, utilization, defective products, actual
unit manufacturing time, and leftovers or shortages at each work center.
Aggregate Planning
In this analysis, it seeks to determine the requirements necessary to meet the anticipated demand of the
company. To do this, the first six months of the year are taken into account in order to understand the
projected demand for each of those months.
According to this capacity analysis, the demand fluctuation strategy is defined, which may include
options such as pursuit, layoff, and hooking, in addition, the costs associated with each of these demand
fluctuation strategies are evaluated.
Other key strategies, such as inventory flow management, outsourcing, and overtime use, are also
considered, each of which includes the costs related to their implementation.
Finally, a comparative analysis of all the strategies evaluated is carried out. Based on the results
obtained, the decision is made to select the strategy that is most convenient and effective for the
company based on its objectives and needs.

Master Production Program:

The Master Production Program (PMP) is an essential tool in the planning and control of production, it
allows to coordinate the demand of Envases De Colombias Sas by determining how many products
should be manufactured and at what time, considering factors such as market demand, available
resources.
We identified that the master program allows us to plan demand by analyzing sales projections to
determine the amount of products that should be produced in specific periods, as well as capacity
planning to ensure that it is sufficient to meet projected demand, inventory management to maintain
adequate inventory levels and avoid shortages or excess of finished products, Production scheduling to
establish a detailed schedule for product manufacturing, optimizing resources and minimizing
downtime.

Purchase Plan

Its main objective is to ensure that the company has the necessary inputs for the production of the
containers, identifying the needs and requirements of materials for the planned production and the
current stocks, the selection of suppliers in which those that meet the criteria such as quality,
competitive prices and delivery time are evaluated and selected.

Conclusion

The comprehensive analysis of the progress of the project reveals the complexity and importance of
coordinating various aspects to achieve efficient management in Envases de Colombia Sas. From sales
forecasting to aggregate planning, Master Production Schedule, and Purchasing Plan, each stage is
integrated to optimize resources, meet market demand, and ensure operational efficiency.

The mixed method of forecasting, with its 58% probability of success, is positioned as the most reliable
option for anticipating production needs. In addition, detailed capacity analysis identifies the bottleneck
in the finishing work center, allowing precise targeting of improvement efforts.

Aggregate planning, demand fluctuation strategies, and benchmarking provide a solid strategic
framework. Informed decision-making is crucial to optimizing costs, managing inventories, and
selecting the most appropriate strategy.
Análisis:

Result of compliance with the Master Program for the Production of Green and Yellow 1/4 Gallon
Containers:
1. Production Efficiency:
1. Compliance with the master schedule to produce 1/4 gallon containers is assessed at 95%
for green containers. This is due to a smooth operation of the machinery and processes on
the production line designated for this color.
2. As for the yellow containers, 98% compliance is achieved, indicating highly efficient
production and good management of resources.
2. Interference in the Production Process:
1. The production of green packaging is affected by 5% due to small interferences in the
supply chain of raw materials specific to this color.
2. On the other hand, the production of yellow packaging faces minimal interference, with
2% of setbacks related to the occasional availability of certain components.
3. Environment and External Factors:
1. The production of green packaging is affected by 2% due to particular environmental
conditions on the production floor, which could be addressed with improvements in the
working environment.
2. For yellow packaging, the environment has a minimum impact of 1%, suggesting greater
resistance to external factors.
4. Recommendations to Improve Utilization:
1. Based on the evaluation, the implementation of training programs for production
personnel is suggested. This focuses on improving efficiency in handling raw materials
specific to the color green and addressing any issues related to the work environment that
affect production.
5. Market and Demand Outlook:
1. The analysis demonstrates that with current compliance, market demand for 1/4 gallon
containers in green and yellow colors is being met.
2. With a 50% utilization for each color, an equitable distribution is achieved that can be
adjusted according to market trends.
In summary, master program compliance is strong, but there are areas of improvement identified that
could further increase the efficiency and profitability of 1/4 gallon container production. Implementing
training programs and addressing specific interferences can help maximize system performance.

https://youtu.be/gjJ0KjydicU?si=CYiQ9uEgHabrhta6

Preparado por: DANIELA VALENCIA, DANIELA DIAZ, MARILIN CERDA

Unidad Organizativa: ADMON DE LA PRODUCCION
Fecha: 30/11/23