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Programme

Production Planning and Maintenance Management

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CONCEPTS
KEY
1
INTRODUCTION TO PRODUCTION PLANNING
2
STRATEGIC FACTORS. DEFINITIONS
3
PRODUCTION PLAN AND CONTROL SYSTEM
4
MRP (MATERIAL REQUIREMENT PLAN)
5
MRP II (PRODUCTION RESOURCES PLAN)
6
CASE STUDY: INDUSTRIAL COMPANY PRODUCTION PLAN
7
CAPACITY MANAGEMENT. "CAPACITY PLANNING PROCESS"
8
CRP. CAPACITY REQUIREMENTS PLAN
9
AVAILABLE CAPACITY AND REQUIRED CAPACITY
10
ORDER PLANNING
11
THE THEORY OF RESTRICTIONS. BOTTLENECKS
12
CARRYING OUT A CAPACITY PLAN
13
PLANT LAYOUT
14
SLP METHOD OF IN-PLANT DISTRIBUTION
15
MAINTENANCE. INTRODUCTION AND GENERAL CONCEPTS
16
MAINTENANCE STRATEGIES
17
MAINTENANCE ORGANISATION
18
HUMAN FACTORS (TRAINING AND SECURITY)
19
EXECUTION OF MAINTENANCE WORK
20
COMPUTERISED MAINTENANCE MANAGEMENT. CMMS
DESCRIPTION

The purpose of this course is to introduce the participant to Production Planning processes from a strategic level to an operational level. It develops how to determine what the market expects of our company and make it compatible with our productive reality, with the objective of fulfilling with our clients, thus defining a correct Service Policy.

A fundamental element in any planning is to know how to manage our production capacity and also establish improvements in the physical distribution of equipment in our plant and "lay-out" to increase this capacity. To this end, this course will see tools and knowledge to optimise resources (material and human) and maximise results, as well as identify and manage the "feared" bottlenecks.

Within a correct planning of the production and the productive capacity it has a fundamental impact to manage correctly the tasks of maintenance of the equipment. Also seen in this module is the large number of technical, technological, operational and management aspects that can change the impact of maintenance work on company results, especially through obtaining the maximum availability of production assets at the lowest cost, ensuring the quality of the final product and the safety of workers. Another important aspect will be the knowledge of the maintenance tasks marked by legal dispositions that are of obligatory fulfillment, or "legal maintenance", whose control and execution guarantees the continuity of the business activity.

Information

Objectives

  • Classify and interpret any type of company using criteria of Productive Process Strategy and Product / Service to decide the most appropriate Service Policy.

  • Understand and master the operation of the Production Plan and Control System.

  • Know what the MRP (Material Requirement Plan) is and what it is used for and manage its calculation.

  • Apply what has been learned and be able to develop a complete and detailed Production Plan.

  • Master and be able to develop a Capability Plan and a Capability Requirements Plan.

  • Master the calculation of Available and Necessary Capacity, and manage their differences.

  • Plan orders according to capacities and control the determination and management of Bottlenecks.

  • Apply and develop the SLP method of in-plant distribution.

  • Manage the main concepts related to industrial maintenance and its internal processes. As well as the different techniques for the execution of an effective and efficient maintenance.

  • Know the optimal management of human resources, contracts and materials for maintenance, focused on improving the availability of equipment.

  • Analyse the current situation of a maintenance department using management indicators and design an excellence roadmap.

MÓDULES

INTRODUCTION TO PRODUCTION PLANNING

  • Current Business Environment.

  • Customer and Consumer Expectations.

  • Objectives and Conflicts in a Company.

  • Competitive Characteristics.

  • Service Policy. Definition.

  • The Productive Area within the Company.

STRATEGIC FACTORS. DEFINITIONS

  • Introduction to the Productive Process Strategy.

  • Models of Productive Process Strategy. Characteristics:

  • Introduction to Product/Service Strategy.

  • Product/Service Strategy Models.

PRODUCTION PLAN AND CONTROL SYSTEM

  • Scheme of the Model.

  • Business Plan (BP).

  • Sales and Operations Plan (SOP).

  • Master Planning (MPS).

  • Material Requirement Planning (MRP).

  • In-Plant Control (PAC).

MRP (MATERIAL REQUIREMENT PLAN)

  • Evolution of the MPS to the MRP.

  • Advantages of MRP.

  • Scheme of Operation of the Dependent Demand:

  • Examples of MRP Calculation.

  • Exercises.

MRP II (PRODUCTION RESOURCES PLAN)

  • Introduction to the concept of MRP II.

  • Schematic of MRP II.

CASE STUDY: INDUSTRIAL COMPANY PRODUCTION PLAN

  • Production and Supply Planning Model.

  • Maintenance, Monitoring and Control.

CAPACITY MANAGEMENT. "CAPACITY PLANNING PROCESS"

  • Concepts of Productive Capacity.

  • Introduction to the Capacity Plan.

  • Capacity Plan Process:

  • Conclusions.

CRP. CAPACITY REQUIREMENTS PLAN

  • Basis of starting point.

  • Required information.

AVAILABLE CAPACITY AND REQUIRED CAPACITY

  • Factors affecting availability.

  • Product Specifications.

  • Measurement and Capability levels. Determination of Available Capacity.

  • Factors affecting needs.

  • Dependencies of Available Capacity.

  • Load Determination.

ORDER PLANNING

  • Introduction to Order Planning.

  • Types of Plans:

  • Programming Criteria.

  • ERP: Finite Capacity vs Infinite Capacity.

THE THEORY OF RESTRICTIONS. BOTTLENECKS

  • Definitions and Concepts.

  • Yield and Productivity

  • Theory of Constraints

  • Classification of Resources

  • Bottle Necks. Detection and Management

  • Rules of the Theory of Constraints

CARRYING OUT A CAPACITY PLAN

  • Implications of available vs necessary capacity management

  • Actions to balance capacity

  • Methods for Modifying Available Capacity

  • Analysis and Control Process

  • Adaptation models

PLANT LAYOUT

  • Starting point. Definitions and Concepts

  • SLP objectives

  • SLP Principles and starting alternatives

SLP METHOD OF IN-PLANT DISTRIBUTION

  • General Description of the Method

  • Product-Quantity Analysis

  • Product Tour

  • Relationship between Activities

  • Relational Chart of Activities

  • Determination of Spaces

  • Relational Spaces Chart

  • Adapting the Chart

  • Evaluation and Selection of Alternatives

  •  Project Approval

MAINTENANCE. INTRODUCTION AND GENERAL CONCEPTS

  • Definition, Objectives and Justification of Maintenance.

  • Consequences of Non-Maintenance.

  • Golden Rules and bases for a correct Maintenance.

  • Causes of Faults or Breakdowns.

  • Types of Maintenance: Classification and current trends.

  • Legal Obligation: Legal and Normative Maintenance.

MAINTENANCE STRATEGIES

  • The current environment of Maintenance.

  • Maintenance Models.

  • Outsourced Maintenance.

  • Application of Strategies.

MAINTENANCE ORGANISATION

  • Factors that intervene in the efficiency of Maintenance.

  • Maintenance development infrastructure.

  • Resource Management and Implementation Staff.

  • Maintenance Plan Preventive - Predictive.

HUMAN FACTORS (TRAINING AND SECURITY)

  • Staff Motivation.

  • Training: Key Factor in Maintenance.

  • Occupational Health and Safety.

EXECUTION OF MAINTENANCE WORK

  • The Work Order.

  • Examples of Quality Management Systems.

  • Evaluation Indices and Management Reports.

  • Failure Analysis.

  • Maintenance Management Tools.

  • Maintenance Audit.

COMPUTERISED MAINTENANCE MANAGEMENT. CMMS

  • Definition, usefulness and minimum requirements of a CMMS.

  • Main characteristics of a CMMS.

  • Purpose and scope of a CMMS.

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