Materials Management and Control

Introduction

Over the last fifty years there have been significant developments in modern manufacturing; when planned properly and executed systematically these theories and models optimize manufacturing effectiveness, thereby increasing the customer satisfaction and profits. During the late sixties the science of managing manufacturing organizations developed the concepts of MRP, Materials Requirement Planning, which has been the single most important factor in taking the productive operations to a new level of success. Manufacturing will continue to be the backbone of the economy in both developed and developing countries; hence it is important that organizations implement tools for improving effectiveness, thereby establishing low cost production position. The service sector of the economy such as tourism, the hospitals, engineering and construction as well as government-controlled operations could also benefit from these best practices of material requirements planning. The value-added process in the manufacturing and service sectors not only improve customer satisfaction through on-time, quality delivery of goods and services but also creates value for the citizens of the country through improved productivity, thereby establishing competitiveness in the global economy. In the final analyses those organizations utilizing the best production planning and inventory control utilizing modern manufacturing principles will assure low cost, high quality provider of goods and services and will become the preferred global supplier.

In order to achieve the stated objectives of becoming a low cost quality supplier of goods and services in today’s global economy the businesses in both manufacturing and the service sector must pay attention to their practices in managing materials. The material requirements planning workshop will examine the best practices and the methodologies of the modern manufacturing theories applicable in both continuous and batch operations. The MRP methodologies effectively address materials requirements, both in quantities and timing, in situations where they are dependent/interrelated on each other. Planned and executed effectively MRP will result in significant savings.

Objectives

This course will address the principles of Material Requirements Planning and how it impacts the production planning and inventory control using the best practices in modern manufacturing theories and practices. Participants will gain greater appreciation to the benefits of positioning their operations and optimize the value from the supply chain.

Training Methodology

MRP is a comprehensive management tool that strives to optimize manufacturing operations by improving the management of materials. Since the expected results of the MRP initiative is strictly based on the competency of resources driving the program, having the right resources with proper training and functioning capability will assure organizational objectives on improved operations.

Participants will be exposed to key manufacturing principles such as:

• The Supply Chain Management and the role of manufacturing in the Supply Chain
• Planning and controlling inventory levels
• The business planning cycle
• Demand Management and Forecasting
• Sales and Operations planning
• Master Scheduling management
• Material Requirements Planning
• Capacity Requirements Planning
• Operations execution and control
• The manpower and resource planning

Who Should Attend?

Plant Managers, Senior Production, Maintenance and Operations Managers, Line Production Supervisors and Production Engineers, Logistics, Materials and Supply Chain professionals, plant superintendents, inventory planners, master planners, master schedulers, production and maintenance first-line supervisors. In addition accounting and financial personnel, Purchasing Agents and those involved with implementing Just-In-Time and Manufacturing Resource Planning initiatives will benefit greatly.

Course Outline

Day 1: Business Concepts and Planning

• Chronology of emerging new technologies in manufacturing
• Key Manufacturing Questions
• Concept of Supply Chain Management
• Classification of Operations
• Business Planning Cycle

Day 2: MRP - Material Requirements Planning

• Material Structure Tree
• Gross Materials Requirement Planning
• Net Materials Requirement Planning
• Master Production Scheduling Overview
• Bill Of Materials
• Key MRP Activities
• MRP Integration Issues

Day 3: MRP II – Manufacturing Resource Planning

• Sales & Operations Planning
• Demand management & Forecasting
• Capacity Planning
• Master Production Scheduling

Sales and Operations Planning

• Anatomy of the S&OP process
• Sales and Operations Planning Activities
• Integration – issues & Challenges
• S&OP measurements

Day 4: Demand Management & Forecasting

• Demand management
• Forecasting techniques
• Resource Planning
• Master Scheduling
• Rough Cut Capacity Planning
• Capacity Requirement Planning

Capacity Planning

• RCCP - Rough Cut Capacity Planning
• CRP - Capacity Requirement Planning
• Plant Scheduling
• Kanban integration
• Supplier Scheduling
• JIT Concepts

Day 5: Master Production Scheduling

• Supply-Side Forces
• Demand-Side Forces
• Lead Time
• Production Forecast
• Manpower Planning
• Special Customer Specifications – SCS
• Master Scheduling Activities