Production Planning and Control in injection molding industries in molding factory
What are production planning and control?
The management and scheduling of production planning and control include the distribution of labor, raw materials, workspaces, equipment, and production processes. In order to meet production demand, it determines the most effective approach to produce finished goods with the necessary lead periods.
Throughout the manufacturing process, two tactics that are referred to as production planning and control cooperate. What to create, when to produce it, how much to produce, and other factors are all included in production planning. To properly optimize the production flow, production planning must take a long-term perspective.
The process of production planning and control is predetermined and involves the use of resources such as raw materials, labor, machinery, etc. PPC is a method for strategically planning each and every action in a lengthy chain of independent actions. To attain optimum efficiency, it is beneficial to make the proper decision at the appropriate time and location.
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To get the best performance out of the production system and meet throughput goals, production control employs a variety of control strategies.
What is production planning?
By effectively allocating internal resources to satisfy client orders or demands, production planning enables producers to work more productively. It addresses the issues of what to create when and how much. It determines the number of raw resources, bill of materials, or alternative bill of materials required to satisfy demand. After that, a practical production plan is created.
What is production control?
Production control provides visibility and reporting by tracking production and measuring performance. Corrective action is started if it is necessary. To attain the highest possible product performance levels, it combines a variety of control techniques.
PRODUCTION PLANNING AND CONTROL BENEFITS
Planning and controlling production has several advantages, such as:
Enhanced efficiency for frequent and prompt delivery
improved supplier communication for buying raw materials
Inventory investment reduction Production cost reduction through improved efficiency
the smooth operation of all production steps
decreased resource waste
reductions in production costs that boost profitability
PRODUCTION PLANNING AND CONTROL OBJECTIVES
Although the goals of production planning and control can differ from business to business, some common goals include the following:
Controls over inventory management
optimal use of the production process and the available resources
Production schedule organization, usually with the aid of dynamic production scheduling software
To ensure that the appropriate kind and amount of machinery, raw materials, and other inputs are available during production
To make sure capacity utilization matches anticipated demand
What goals do production planning and control seek to achieve?
The following are the main goals of production planning and control:
Improve the use of resources and their scheduling to fulfill production demands.
Establish a productive schedule.
Have the necessary resources on hand.
Maintain proper stock levels.
Increase internal resource productivity, human, work centers, machines, tooling, etc.
Boost client satisfaction
Make sure the appropriate person is allocated to each process.
Work with other departments to coordinate, sales, customer service, purchasing, etc.
The heart of any industrial unit is the production planning and control department. It also involves long-term planning, demand management, master production scheduling, and more. Forecasting a product’s demand is the first step in the planning process. The production plan is made using these predicted data and the internal resources available.
An approach for planning a chain of events that helps manufacturers be in the right place at the right time is called production planning and control. It enables them to maximize the efficiency of their available resources. Additionally, it covers the activities of other divisions including sales, marketing, and procurement.
What advantages do production planning and control offer?
Among the several advantages of production planning and control are:
Increased manufacturing capacity makes sure that both workers and equipment are fully used. As a result, expenses are kept low, productivity is raised, and profitability is increased. Planning for expansion and identifying areas for improvement are both beneficial.
Reduced inventory expenses – manufacturers can only keep what is necessary. The program has a Just-in-Time scheduling mechanism and can estimate demand. Costs are kept low since there is no inventory overstock.
On-time delivery Can aid in ensuring efficient production and quick deliveries. Customer satisfaction is higher when deliveries are made on time. As a result, customers stay longer and refer more people.
Better material sourcing indicates when materials should be bought for production. Knowing when to order and what is required to meet consumer and production demands is made easier with the use of this information. Knowing when to place an order enables procurement to shop around for the best prices. Additionally, this promotes financial savings and strengthens connections with suppliers.
Production procedures that are streamlined make sure that the necessary supplies and internal resources are on hand when they’re needed, as well as what capacity is accessible and when. This maintains the production process efficiently. Additionally, it increases worker happiness by removing frustration brought on by production and workflow interruptions.
The elimination of material shortages or surpluses results in little resource waste. As a result, less employee time is squandered. Inventory that is not used does not tie up capital. Because delays that result in rejected materials are minimized, there is reduced manufacturing waste.
The manufacturing industry’s role in production planning and control
In the industrial sector, production planning and control play an important part in making sure that supplies and machinery are accessible when needed and that operations go well.
In the electronics business, component traceability and procurement provide unique difficulties that need careful planning. The most productive and lucrative production is the ultimate objective.
What function do production planning and control have in the manufacturing industry?
The resources for production are always ready when needed thanks to production planning and control. To maintain optimal production, materials, tools, and labor must be available as needed. It serves as the foundation of a manufacturing company. The more a company grows, the more PPC is necessary for successful functioning.
How are production planning and control stages carried out?
Planning establishes who, what, and how will be created. It creates the production schedule for the necessary manpower, tools, facilities, and raw materials.
The creation of a production plan is assisted by pertinent information from numerous sources. data from sales, such as order quantity and delivery date promises. It can also be necessary to request product specs from the engineering division. The planning stage contributes to maintaining a simplified production process.
The factory’s flow of raw materials is controlled by routing. The sequence is used to convert raw resources into finished products.
To calculate the length of the production process, it is crucial to schedule each step and coordinate every production process. Routing demonstrates the quantity and caliber of resources and materials required. Additionally, it displays the processes used and the location of manufacturing.
The “How,” “What,” “How Much,” and “Where” of production are managed via routing. The procedure is systematized, and resources are used most effectively.
The “when” of the operation is highlighted by scheduling. It seeks to maximize the time allotted for the operation’s completion.
According to Kimball and Kimball, the schedule includes:
The calculation of the amount of time needed to complete the full series according to plan, taking into account all relevant aspects.
Organizations manage the time component using a variety of schedules. These comprise the daily schedule, the operation schedule, the master schedule, and more.
The amount of work that is being placed on humans or equipment is examined during loading. To the work already scheduled for the machine or workstation, the total time required to complete new work is added.
More orders can make up for the underload if a machine or workstation has available capacity. The use of proactive measures helps avoid bottlenecks in cases of capacity overload. Options include adding a shift, asking for overtime, bringing in workers from another shop, or hiring a subcontractor.
The release of orders and accompanying instructions is known as dispatching. It adheres to the scheduling and routing instructions. This procedure makes sure everything is ready for the workers to perform their duties.
The following are the components of “Dispatching”:
Release equipment or supplies that are necessary for production.
Send out orders or plans to start the work
Keep the records up to date throughout.
launch the control process
Work should be cascaded from one procedure to another.
Follow-up, also referred to as expediting, identifies production process flaws, bottlenecks, and gaps. This stage involves measuring the actual performance throughout and comparing it to the predicted performance.
Problematic areas need to be addressed. Follow-up identifies the problem’s source and aids in its solution. For instance, is it due to an uncommon event if timetables are not met? Or does something need to be changed? To fix the problem, the production manager might have to change the production targets, loads, or timetables.
To make sure everything under the production’s scanner conforms to the correct quality standards, inspection sessions, and audits should be held.
The results of the aforementioned actions will be evident, and you can then take appropriate action to address any problems. To improve the process efficiency moving forward, this is essential.
Contact Optel online right away to learn more about our software for electronics manufacturing or about the processes used for production planning and control in a manufacturing organization.