Module Information Production Planning and Control

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1 Module Title Module Code Module Information Production Planning and Control EMM MODULE SUMMARY Aims and Summary The intent of this module is to teach students the importance of manufacturing execution systems which ensures that the right product, at the right time, at the right price and quality is delivered to customers. This module addresses the techniques available for production planning and scheduling such as forecasting, business and aggregate planning MRP I to ERP, inventory management, master production schedule, and resource planning. This enables students to co-ordinate inputs from sales and marketing, the supply chain and manufacturing to produce effective schedules. The student will have knowledge on modern concepts of constraint management, JIT; pull systems etc from a scheduling point of view. Procedures for integration of data into the system to support sales, the product, manufacture, finance and resources will also be taught. Students are trained to plan and schedule production using Preactor software. Module Size and Credits Module size CATS points 10 ECTS credits Open / restricted Availability on/off campus Single N/A Total student study hours 100 Number of weeks Department responsible Academic Year 2012 Restricted On Campus 5 weeks Full-Time or 8 weeks Department of Mechanical and Manufacturing Engineering Entry Requirements (pre-requisites and co-requisites) Normally to be qualified for entry to the Postgraduate Engineering Programme Excluded Combinations None Composition of Module Mark (including weighting of components) Full-time / Part-time : 50% Written Examination and 50 % Assignment Pass Requirements A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment and overall 40% marks are required for a pass Special Features 80% attendance in theory and 80% attendance in laboratory are required. It is likely that considerable time will be spent in School facilities outside of normal timetabled class time. Courses for which this module is mandatory M.Sc. [Engg] in Engineering and Manufacturing Management Ver: 4 November 2011 MI EMM2517 Page 1 of 5

2 Courses for which this module is a core option M.Sc. [Engg] in Technology and Engineering Management 2. TEACHING, LEARNING AND ASSESSMENT Intended Module Learning Outcomes On successful completion of this module, the student should be able to: 1. Critically appraise MRP and identify need for MRP II and describe benefits and weaknesses of ERP 2. Demonstrate levels of planning business planning at corporate level to shop floor planning at company level 3. Demonstrate backward & forward scheduling and understand nature of bottlenecks for optimisation of work schedule 4. Design a Kanban system 5. Demonstrate the ability to interact with suppliers, describe effect of short call off times, and propose methods to help suppliers integrate successfully with customer PPC systems Indicative Content Class Room Lectures 1. Company Level Control Systems: Concepts of a PPS System, Performance measurement systems and linkages to competitiveness, Understanding of Technical words used in PPS. Forecasting, Business and Aggregate planning MRP and MRP II, Inventory Management, Master Production Schedule, Resource planning 2. Distributed Control Systems: Finite and Infinite Loading, Scheduling, Batching Methods, Sequencing, Algorithmic based sequencing and Simulation based sequencing and Sequencing rules such as shortest processing time (SPT), first come first serve (FCFS), least slack time (LST), Critical ratio etc., Expediting, Input-Output control. 3. Scheduling Techniques: Forward scheduling, Backward scheduling, and Bi-directional scheduling. Finite and Advanced Planning Scheduling with Preactor software. 4. Local Production Control Techniques: Production planning and scheduling in a Lean, JIT, and Optimized Production Technology (OPT) environment. Synchronisation of outputs, Line Balancing, Line of Balance, Scheduling for Smooth flow 5. Impact on the Supply Chain: Supply chain management issues like Customer and Supplier development, Customer and Supplier relationships, Kanbans and Kanban principles, Push and Pull production systems. Laboratory Practice 1. Visit to industry to experience the production planning and scheduling process 2. Exercises on Finite Scheduling using Preactor Software Ver: 4 November 2011 MI EMM2517 Page 2 of 5

3 Teaching and Learning Methods 1. Theoretical Knowledge a. Face to face lectures 2. Laboratory Practice (Skills) 3. Application Orientation and Problem Solving a. Reading b. Research c. Written Examination d. Assignment Solving and Documentation 40 hours 30 hours 30 hours Method of Assessment Part-A Examination [50% Weightage] 1. Viva/Presentation on a specified topic... (10%) 2. Field work / Laboratory test... (10%) 3. Written examination...(30%) Part B Assignment [50% Weightage] Students are required to submit a word processed assignment report. Assessment Learning Outcomes Part A X X X Part B X X X X Both written examination scripts and assignment reports will be double marked. Re-assessment A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment are required for a pass in the module. A student failing in any one of the components or both is considered as FAIL in the module. A failed student is required to retake the module at the next opportunity. A maximum of 3 attempts including the original are allowed. Date of Last Amendment November Ver: 4 November 2011 MI EMM2517 Page 3 of 5

4 3. MODULE RESOURCES Essential Reading 1. Module Notes Recommended Reading Books 1. Mann F.L. (2000) Production workflow concepts and techniques, Prentice Hall 2. Eilon and Samuel. (2000) Elements of Production Planning and Control, Universal Publishing 3. Goldratt Eliyahu M. (2003) Production the TOC way, North River 4. Black and John R. (2004) World Class Production System Lessons of 20 years in persuit of World Class, Viva books 5. Vollman and Thomas E. (2005) Manufacturing Planning and Control for Supply Chain Management, McGraw Hill 6. Pannerselvam R. (2005) Production and Operation Management, Prentice Hall 7. Chary S N. (2006) Production and Operation Management, Tata McGraw Hill 8. Krajewski, Ritzman and Malhotra. (2007) Operations Management, Prentice Hall Publications 9. Khanna R.B. (2007) Production and Operation Management, Prentice Hall 10. Anderson George W. (2008) SAP Planning, Best Practices in Implementation, Pearson Journals 1. International journal of operation and production management, Emerald Group Publications Internet Sites Laboratory Hardware: PCs Software: Preactor Scheduling Software Software Manual: Preactor Manual 4. MODULE ORGANISATION Module Leader Name Vijaya Kumar S Room B-504 Telephone number Date and Time of Examination As per time table Subject Quality and Approval Information Subject Quality Group / Subject Board Subject Assessment Board Mechanical and Manufacturing Engineering Postgraduate Engineering and Management Programmes Ver: 4 November 2011 MI EMM2517 Page 4 of 5

5 Shortened title PPC Date of approval by MARP November 2011 Ver: 4 November 2011 MI EMM2517 Page 5 of 5

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