The Macro Production Planning and
Control Systems follow very simple and well established principles.
To produce the Correct Product to meet demand at the required time
To do so at the lowest Practical Cost
To do so with the shortest practical lead
To do so with the maximum degree of simplicity and flexibility
To make the available resources as efficient as possible
The system is designed to
allow a wide range of facilities and options. These are not compulsory and the
user need only use the facilities that he requires.
To ensure that the correct products are manufactured,
at the lowest practical cost, to be available at the right time.
Resource Capacity Planning to enable the user to analyse the available
capacity of men and machines against capacity required by the order
situation or the actual production plan.
To assist in the translation of the over-all requirement into a production
To provide facilities to plan the production schedule in detail and ensure
that production resources are fully utilised without unnecessary under or
Material Requirement Planning to enable the user to correctly schedule the
ordering of raw materials to meet the requirements of the production
To achieve this the Macro system
provides three main subsystems:
Product Net Requirement Planning
Production Planning including Materials Planning and Resource Planning.
first phase of Production Planning is deciding what products to manufacture.
The basic planning reports to provide this information are:-
Sales Forecast Sub-system.
This is an optional facility which allows the recording of Sales Forecasts by
product or product group by period (week or month) for as many periods needed
for the planning horizon. This facility is used for companies who manufacture
fully or partially to a sales or manufacturing plan.
Master Planning Facility
allows the user to load a production budget by product by period (week or month)
for as far in the future as needed. The Master Plan is basically a long term
planning aid. Materials planning and capacity planning can be carried out
against the Master Plan.
Order System Reports. The Customer Order Systemrecords all orders received for future
delivery. The order system provides many different types of order analysis
including time based delivery requirement analysis
Current Work in
Progress Stock Requirement and Availability Report.
. The Macro system basis much of its product requirement planning facilities on
the concept of stock and availability ie. what stock is available, and when it
is available. This takes into account the stock on hand, stock becoming
available at a later date and the current and future demand on that stock. The
stock and availability is the key report which identifies, by time period, the
stock that is required and the stock that will be available, with stock
shortfalls by period, cumulative and in total. Requirements are obtained from
the Sales Forecast and/or the Customer Order Book. Availability is determined
from the Stock on Hand, the Purchase Orders Outstanding, Production Plan and
Work in Progress. This report has the ability to explode a product to an
unlimited number of levels and to carry out independent stock and availability
calculations at each level. i.e.. it operates at the component level as well as
the product level. The result of this process is available on a report or as an
Materials Requirement Planning.
The objective of the Material Requirements
Planning is to ensure that the Materials required to complete the planned
production are available, and if they have to be ordered, that they should be
ordered in good time, and received before they are needed. Materials
Requirement Planning Reporting is the next level of breakdown of the Production
Reports are available at several levels:-
M.R.P. based on orders received but not dispatched (or
on the Production Master Plan). This report is produced well before
production start to check materials on hand, and on order, to requirements
based on the required production level. This is normally a long term
MRP based on the Stock and Availability Report
M.R.P. based on the actual production plan. The source of the quantities,
and product to be produced is by production period. It is normally printed
as soon as a detailed production plan is loaded for a particular period.
The M.R.P. report has the same explosion and multi-level facilities as the
Stock Requirement and Availability Report. i.e. Explosion to an unlimited
number of levels and full Stock and Availability planning at each level.
All Material Requirements Reports follow the same basic principles. The
product requirement is determined from one of several optional sources.
(Stock Requirement and Availability Shortfall, Production Plan, Master
Production Plan, Sales Forecast, Order Book etc.) The system uses the Bill
of Materials, which describes the exact make-up of each product to determine
the unit material requirements. Stock on hand is obtained from the Raw
Materials Stock Master data base. Stock on order is obtained from the
Purchase Order data base . The M.R.P. reports are time based and show
shortfalls and availability/net shortfall to as many levels of explosion as
required. All shortfalls are shown in two periods, the period required, and
the period in which ordering is required to ensure on time delivery.
is similar to Materials Requirement Planning, except that the resources that are
analysed are capacity related.
These can be:-
Machines or Processes or Cost Centers. Machines can be recorded
individually or by machine group. Any other production facility can be
defined as a production cost centre.
Labour may be recorded in as many categories as required.
The capacity information (number of
installed units, capacity hours per production period resource efficiency rating
and availability) is stored on the relevant record in the Resource Master File.
This enables the system to calculate the total availability of each resource.
The Bill of Materials/Standard
Costing System contains details of the resources required to manufacture each
product. The combination of the Production Plan quantities and the resource
requirement ex the Bill of Materials enables the system to calculate the total
requirement of each resource.
Planning Reports are all time period based. Resource planning can also be
expanded to an unlimited number of levels.
Planning Reports are available from:-
Stock and Availability Data Base
The Production Master Plan
Production Job Master File
The Master Scheduling Master File
An optional Master Scheduling System will allow the user to carry out Capacity
Planning on a closed loop finite capacity basis. The plan may be modified and
replanned as often as required until an acceptable plan is created. This may
then be copied to the Production Job Master File to become the actual plan.
This facility creates the actual job schedule, job by job, on a practical basis
and provides finite capacity planning i.e. once a resource is fully loaded for a
period later jobs are planned to commence at a later date when the resource is
available for use. The system provides for final product manufacture and
sub-assembly. i.e. the time relationship between component manufacture and the
final product is supported.
The system contains a model of the
companies production resources and a full factory calendar for the period being
planned. This model is used to create a model of the capacity available (fully
time based). The Production Jobs, or Stock and Availability reporting is used,
with the Bill of Materials, or the Production Routing, to create a model of the
capacity required (also time based).
The scheduling system matches requirement to availability on a finite basis (ie.
a resource cannot be overloaded - over use of capacity moves the process to a
later time period, so that the effect of over utilisation is late delivery)
Information that may be modified for
each trial schedule is as follows:-
Production Units or Machines to be used in the manufacturing process
Production Planning level i.e. The level of detail to which the current
trial plan must be calculated
Job Planned Start Dates
Efficiency of machines or processes
Utilisation time of processes
PRODUCTION PLANNING AND SCHEDULING
To fully utilize this functionality, the following
products should be evaluated