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Manufacturing Planning and Control

Planning for and controlling the resources

To get the most value out of our resources we must design production processes that make products most efficiently. Managing the operation means planning for and controlling the resources used in the process.

Manufacturing Planning and Control, MPC, is responsible for the planning and control of the flow of materials through the manufacturing process.

Objectives: This course provides you with profound insights into how to coordinate the supply, production and distribution functions. It will also teach you how to balance conflicting objectives to minimize the total of all the costs involved and maximize customer service.

Participants: People working with production planning and development, production engineering, inventory management, purchasing, sourcing, and other business professionals wanting to improve their skills in manufacturing planning and control.

Qualifications: Participants should have knowledge of basic logistic principles and some insights into production planning.

Training Method: Manufacturing Planning and Control is a Premium course and is studied over the internet via our e-learning platform Instant education. Read more about the training method E-learning - Premium courses.

Course Length: Approximately 35 hours active study time, depending on previous knowledge. Each student has access to the course for 6 months.

Price: 667 Euro / student
740 USD / student

Prices excluding VAT.
For large-scale education projects request quotation.

Online price:

652 EURO / student
724 USD / student

Prices excluding VAT.

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Course contents:

Part 1

Managing the Operation

Planning for and controlling the resources used in the process to get the most value out of them.

Conflicts in Objectives

Often a departmental objective is maximized without considering the effect it has on other parts of the company.

Materials Management

Materials management is a coordinating function responsible for planning and controlling materials flow.

Structuring the Flow of Material

Two ways to structure the flow of material are manufacturing planning & control, and physical supply and distribution.

What is Manufacturing?

Production processes are as varied as the products they produce.

The Concept of Manufacturing Strategy

The strategy seeks to ensure that the right things are being done and that the right things are done well.

Basic Production Systems

The production system used by a company should be the one that is best able to provide the manufacturing outputs demanded by the customers.

Definition of Production Systems

Overview of the basic production systems.

Manufacturing Planning and Control System

To be profitable it is essential to have a good planning and control system.

Inputs to the Manufacturing Planning and Control System

There are five basic elements of information to the input of the manufacturing planning and control system.

Part 2

Making the Production Plan

Production planners must devise a plan to satisfy market demand with available resources.

Basic Production Strategies

There are three basic strategies that can be used in developing a production plan.

Developing Strategies into Plans

The differences between a make-to-stock and a make-to-order production plan.

Resource Requirements Planning

The process of converting the production plan into the demand on key resources of the company.

Master Production Schedule

The master production schedule is a vital link in the production planning system.

Developing a Master Production Schedule

The plan must satisfy customer demand, be within the capacity of manufacturing and be within the guidelines of the production plan.

Master Scheduling Options

The master production scheduling should take place where the smallest number of product options exists.

Planning Horizon

The planning horizon is the time span for which plans are made.

Production Planning, Master Production Scheduling, and Sales

The relationship between production planning, master production schedule, and sales.

Time Fences

To help in the decision-making process, companies establish planning zones divided by time fences.

Nature of Demand

There are two types of demand, independent and dependent.

Part 3

Material Requirements Planning

Material requirements planning is a system used to avoid situations where parts are missing.

Inventory Records Information

A major input to the material requirements planning system is inventory records.

Bill of Materials

The bill of material shows all the parts required to make one of the products.

Detailed Material Planning Options

The use of detailed material planning approaches depends importantly on the design characteristics of the production process.

Time-Phased Planning

Time-phased planning for individual components is carried out with material requirements planning approaches.

Exploding and Offsetting

This is the process of multiplying the requirements by the usage quantity and then placing them in their proper period based on lead time.

Gross and Net Requirements

Calculating quantities to be produced or purchased.

Releasing Orders

Authorization to buy or to make the required components needed in the material requirement planning.

Overview of Basic MRP Techniques

Some basic concepts, terms, and calculation steps.

Rate-Based Planning

The primary objective is to establish rates of production for each part in the factory.

Material Planning and Aspects of Marketplace

Detailed material planning approaches related to key aspects of marketplace requirements and manufacturing.

Capacity Management

Capacity management occurs at all levels of the planning process.

Capacity Planning

The process of determining the resources required to meet the priority plan.

Capacity Planning Levels

The three planning levels and the methods needed to make that capacity available.

Capacity Requirements Planning

The capacity requirements plan occurs at the level of the material requirements plan.

Available Capacity

The capacity of a resource to produce a quantity of output in a given time period.

Required Capacity

The capacity needed to produce a desired output in a given time period.

Making the Capacity Requirements Plan

This plan should be a detailed workable plan that meets the priority objectives and provides the capacity to do so.

Part 4

Production Activity Control

It is responsible for executing the master production schedule and the material requirement plan.

Manufacturing Systems and Production Control

There are a variety of systems for production activity control dependent on the manufacturing process.

Scheduling System Options

There are two basic approaches to scheduling systems for material planning: material requirements planning and just in time.

Scheduling Manufacturing Orders

The objective is to meet delivery dates and to make the best use of manufacturing resources.

Manufacturing Lead Time

Manufacturing lead-time is the time normally required to produce an item in a typical lot quantity.

Reduction of Manufacturing Lead Time

Scheduling methods which can be used to reduce manufacturing lead time.

Scheduling Bottlenecks

Work centers, fed by bottlenecks, have their throughput controlled by the bottleneck.

Managing Bottlenecks

Scheduling and controlling the bottlenecks is extremely important for the throughput of a system.

Implementation of Shop Orders

A shop packet usually contains the shop order information.

Controlling Progress of Shop Orders

To control progress, performance has to be measured and compared to what is planned.

Input/Output Control

The input/output control system is a method of managing queues and work-in-process lead times.

Priority Control

Control of priorities is exercised through dispatching.

Production Reporting

Production reporting provides feedback of what is actually happening on the plant floor.

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