When making a production plan, you should pay attention to the following matters.
First, the load analysis
Second, the content, essence and conditions of the production plan
III. Production Types, Characteristics and Countermeasures
Four, the eight steps of planning and production control
Five, production plan-the time factor of each stage.
Six, production priority rules
Seven, production planning and scheduling MPS
Eight, insert a single, add a single output plan and contingency methods.
Nine, emergency prevention and response
Control of production planning time
Production planning-consider the time factor of each stage.
1) Time required for product design (for new models)
2) Time required from receipt of the order to production planning and material analysis
3) Time required for purchasing materials (procurement cycle)
4) Time required for incoming inspection of materials (including time required for waiting for processing)
5) Time required for production
6) Time from the completion of finished products to the preparation for shipment
How to control the production schedule? Production schedule control runs through the whole production process, and all production activities from production process preparation to finished product warehousing are related to production schedule. Traditionally, people equate production schedule with production plan, because customers care about whether they can get finished products on time, so enterprises also focus on the completion schedule of finished products, that is, production schedule.
In theoretical discussion, the concept of production control system is often used, but in actual production activities, it is difficult to find the control system from the organizational structure of production system. Production managers are usually unaware of the existence of control systems. But the control system does exist objectively, especially the function of schedule control is very powerful, but many control functions are scattered in several management departments. The reasons for this phenomenon are: on the one hand, enterprises recognize the importance of production schedule and send special personnel to deal with this matter; On the other hand, it reflects the lack of understanding of control theory and exposes the characteristics of poor systematicness in actual operation.
1, inventory should change.
The reason that affects the production schedule comes down to the lack of effective running time of equipment, which affects the production schedule. For example, according to the plan, the normal operation of the factory should be 7.5 hours/shift. Now, due to various reasons, the production is stopped too much, and the operation time is less than 7.5 hours/shift, and the production is short. When there is a shortage of production, it is the easiest way to establish sufficient inventory and make use of insufficient inventory. This is also a very effective way to deal with the shortage of production. However, enterprises have also paid a heavy price for this, and the huge inventory system has occupied a lot of inventory losses. This method does not solve the problem from the root, but it is unreasonable to let the inventory management department take full charge of schedule control. Nevertheless, this is still the main means for enterprises to cope with insufficient production.
2. Emergency repair equipment
Equipment failure is the most important reason for insufficient production in many enterprises. Reducing equipment failure rate and shortening equipment repair time are also widely used measures in schedule control. Establishing a complete and strict maintenance system is an effective measure to reduce the failure rate of equipment. However, most enterprises think that the probability of equipment failure is random and unpredictable. Because of the busy production tasks, they often do not pay attention to equipment maintenance, and the system is ineffective, focusing on emergency repair after failure. In order to shorten the repair time, the repair method of replacing parts is adopted, so it is necessary to establish a large-scale spare parts library.
Step 3 work overtime
Time resources are rigid, and lost time cannot be recovered. Generally, the lost machine time can only be made up by working overtime, which requires overtime pay. However, if the equipment runs in three shifts, there is no possibility of overtime and the loss is hard to recover. Another situation is that even if you can work overtime, you can't keep up with the progress, that is, the key equipment has serious failures and the repair time is longer than when the inventory can maintain production. This is because the equipment was not repaired after the inventory was exhausted, which led to the shutdown of the whole line. Even if the equipment is repaired and overtime production is carried out, it can't make up for the loss of production stoppage across the board.
4. With the management function of daily affairs cleaning, colleagues can assign tasks to each other and check his schedule to know whether it is completed. It can reasonably let employees plan their work schedules, and let managers know their work saturation, work progress and so on in time. In this way, it can be done easily whether the individual completes the work efficiently or works as a team. The core functions of Nissin are schedule management, task collaboration and work notes, which are organically combined to make the work experience easy.
How to control the completion of the production plan is a plan for the whole production operation system of the enterprise, a plan for the production tasks such as product variety, quality, output and output value that the enterprise should achieve during the planning period, and an arrangement for the production schedule of the product. It is not a reflection of a certain number of production posts or production activities of a production line, nor the details of product production and the arrangement of some specific production resources such as machines, equipment and manpower, but a programmatic plan to guide the production activities of enterprises during the planning period.
An optimized production plan must have the following three characteristics:
1) is conducive to making full use of sales opportunities and meeting market demand;
2) It is beneficial to make full use of profit opportunities and minimize production costs;
3) It is beneficial to make full use of production resources and minimize the idleness and waste of production resources.
On the one hand, the production plan refers to the plan that meets the customer's requirements of "delivery, quality and cost"; On the other hand, it enables enterprises to obtain appropriate benefits and make appropriate plans for the preparation, distribution and use of the three elements of "materials, personnel and machinery and equipment".
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Production planning task
1, ensuring delivery date and output;
2. Make the enterprise keep the workload (load) commensurate with its production capacity and the appropriate operating rate;
3, as a benchmark for material procurement;
4. Maintain the inventory of important products or materials at an appropriate level;
5. For the long-term production increase plan, make supplementary arrangements for personnel and mechanical equipment.
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Contents of production plan
1, what to produce-product name, part name;
Example: A kind of cam in auto parts industry, name code: kj908.
2. How much has been produced-quantity or weight;
Because the guest order needs 10000 pieces, the actual production should consider the generation of waste products, and we need to put into production 10500 pieces to ensure the delivery quantity of 10000 pieces.
3. Place of production-departments and units;
Due to the characteristics of the manufacturing industry, it is obvious that we mainly accomplish the indicators in the production department, and the refinement is the processing between the production process teams, including: casting, forging, lathes, milling machines, high-frequency quenching, grinding machines, cleaning and so on.
4. When is it required to be completed? Time limit and delivery date.
If the delivery date of the customer's order is required to be on the 20th of this month, the production and completion of the company should be completed before the 20th to ensure that the customer can receive the goods within the time limit.
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The purpose of production planning
1, the basis of material demand planning;
2. The basis of capacity demand plan;
3. Basis for making other relevant plans.
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Type of production plan
According to different properties, there are various types of production plans, as shown in the following table:
Divide object categories into time periods
Large-scale planning (long-term) long-term production planning product group 2-3 years season
The annual production plan product group and product category are 1 month.
Mid-term schedule (mid-term) March-June production plan product season, semi-annual week and month.
Month, production plan, products, parts, month, day, etc.
Small plan (short-term) weekly production plan, product category and part category.
Daily production plan, product type, part type, date and time
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Conditions that the production plan should meet
1, the plan should be the result of comprehensive consideration of all relevant factors;
2. Must have basic production planning ability;
3. The thickness of the plan must conform to the content of the activity;
4, the plan must be issued within the necessary period.
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Production planning standard
1. Operating plan standard
Operating processing sites;
-The planning standard is gb * * * * where gb refers to enterprises produced in China and * * * refers to industry names); The processing plant can be outsourced or produced in the company, and the specific production unit is the production department.
Type and sequence of operation and treatment;
Examples; Category refers to how many processes a product needs to be processed. For example, the above-mentioned cam processing, the order refers to what to do first, and then what to do according to the completion of cam manufacturing, that is to say, all the processes for producing cams are arranged.
Standard working hours, etc.
2. Standards for process planning and standby capacity planning
Load benchmark of operation and machining process.
Competency benchmarks for operating and processing processes;
-Process planning refers to production and production processes, and standby capacity planning refers to the difference between the enterprise's own production capacity and the existing production capacity. For example, my enterprise produces 65,438+0,000 pieces every day, so I now produce 800 pieces, which means that the resources provided by the enterprise can produce up to 200 pieces. When the total output exceeds 65,438+0,000 pieces, the enterprise's production capacity is saturated. For example, at this time,
3. Standards for materials and parts planning
Parts composition list and parts list;
Setting a dividing groove and a supply dividing groove;
Batch size and output rate.
4. Progress standard
Processing and assembly benchmark schedule;
Batch.
5. Standards for preparing inventory plans
Inventory management segmentation slot;
Order cycle;
Order point and order quantity;
Safety stock, maximum stock and minimum stock.
The above planning standards should be revised and maintained in time whenever they change!
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Production planning index
Making production plan indicators is an important content of production plan. In order to effectively and comprehensively guide the production activities of enterprises during the production planning period, the production plan should establish a production index system with four categories of indicators as the main content: product variety, product quality, product output and product output value.
1, product variety index
Product variety index refers to the name, model, specifications and types of products produced by enterprises during the reporting period. It not only reflects the ability of enterprises to meet social needs, but also reflects the professional level and management level of enterprises.
The determination of product variety index should first consider market demand and enterprise strength, and be determined according to the product variety series balance method.
2. Product quality indicators
Product quality index is one of the important indexes to measure the economic situation and technical development level of enterprises. The product quality is controlled by several quality control parameters. The unified provisions of quality quotation have formed quality technical standards, including international standards, national standards, ministerial standards, enterprise standards and internal standards of enterprises.
3. Product output index
Product output index refers to the physical quantity produced by an enterprise to meet the product quality requirements in a certain period of time. The product output calculated by physical quantity reflects the development level of enterprise production, and is the basis for formulating and checking the output completion, analyzing the proportional relationship between various product quality inspections, balancing product distribution and calculating the production index of physical quantity.
Break-even method and linear programming method are mainly used to determine product indicators.
4. Product output index
Product output value index is an output index expressed in currency, which can comprehensively reflect the achievements of enterprise production and operation activities, so as to compare different industries. According to the specific content and function, it can be divided into three forms: total industrial output value, industrial commodity output value and industrial added value.
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Master production plan
Production planning is the core of the internal operation of factory management. An excellent factory, its internal management should be around the production plan. Production plan includes monthly plan, weekly plan and daily plan. However, with the use of MRP, "master production planning" has become the core of controlling the internal operation of the factory.
Master production plan
First, the meaning of MPS
Master production planning is a phased method to plan the quantity and delivery date of the final products that an enterprise will produce. Master production plan is a kind of advance production plan, which gives the production quantity of a specific project or product in each planning period. Effective master production plan is the commitment of production to customer demand, which makes full use of enterprise resources, coordinates production and market, and realizes the business objectives expressed in the production plan outline. Master production planning plays a leading role in planning management, which determines the objectives of all subsequent planning and manufacturing activities. In the short term, it will be the basis of material demand planning, parts production planning, ordering priority and short-term capacity demand planning. In the long run, it will be used as the basis for estimating the demand for resources such as production capacity, storage capacity, technical personnel and capital of our factory.
Second, the principle of MPS preparation
Master production planning is to determine what to do according to the enterprise's ability, and to achieve the goal of production planning by arranging production in a balanced way, so that enterprises can improve customer service level, inventory turnover rate and productivity, and update them in time to maintain the feasibility and effectiveness of the plan. There can be no items in the master production plan that exceed the available materials and possible capacity. Some basic principles should be followed when making the master production plan.
? * The principle of least projects: arrange the master production plan with the least projects. If there are too many items in MPS, it will be difficult to forecast and manage. Therefore, according to different manufacturing environments, different levels of product structure should be selected to prepare the master production plan. In the manufacturing and assembly process of product structure level, the number of products (or components) selected is minimized to improve management review and control.
? * Principle of independence and concreteness: It is necessary to list practical and concrete constructable projects, not some task groups or planned list projects. These products can be broken down into identifiable parts or components. MPS should list the actual items to be purchased or manufactured, not the planned list items.
? * Key project principle: list the projects that have a significant impact on production capacity, financial indicators or key materials. Projects that have a significant impact on production capacity refer to projects that have a significant impact on the production and assembly process. For example, some large-scale projects, projects that cause capacity bottlenecks or projects that pass through key work centers. For financial indicators, it refers to the projects that are most critical to the company's profit and efficiency. Such as high manufacturing cost, expensive spare parts, expensive raw materials, high production process cost or special requirements for spare parts projects. It also includes those relatively cheap projects, which are the main source of profits for the company. For key materials, it refers to those projects with long delivery time or limited suppliers.
? * Principle of comprehensive representation: the planned project should represent the products produced by the enterprise as comprehensively as possible. MPS should cover as many arrays as possible in the MRP plan driven by MPS, reflecting as much information about manufacturing facilities as possible, especially bottleneck resources or key work centers.
? * Principle of appropriate allowance: leave appropriate allowance, and consider the time of preventive maintenance of equipment. Preventive maintenance can be arranged as a project in MPS, or the capacity of work center can be reduced according to the time of preventive maintenance.
? * Appropriate stability principle: appropriate stability should be maintained during the validity period. After the master production plan is formulated, it should be properly stabilized within the validity period. The practice of arbitrarily changing only according to subjective wishes will destroy the original reasonable and normal priority plan of the system and weaken the planning ability of the system.
Third, the object of the main production plan
The planned object in the master production plan is mainly the finished product after the product series in the production plan is concretized, which is generally called the final project. The so-called "final project" is usually an independent demand part, and its demand exists independently of the demand for other materials. However, due to the different planning scope and sales environment, the final project has different meanings as the planning object.
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Steps to make a production plan
Production planning must follow four steps.
(1) Collect data and study item by item. Resource information and production information required for making production plan.
(2) Make optimization plans and make overall arrangements. Initially determine the production plan indicators, including the optimization of output indicators, the determination of quality indicators, the reasonable collocation of product varieties, and the reasonable arrangement of product production schedule.
(3) Prepare the draft plan and balance the production plan. Mainly the balance between production indicators and production capacity; Calculate the guarantee degree of the main production devices and production areas of the enterprise to the production tasks; The balance between production tasks and labor, material supply, energy and production technology preparation capacity; Balance between production indicators and indicators such as capital, cost and profit.
(4) Discuss the revision and finalization for approval. Through comprehensive balance, make appropriate adjustments to the plan and correctly formulate various production indicators. Report to the general manager or the superior competent department for approval.
At the same time, the production plan should pay attention to the overall situation, efficiency, balance, batch size and adaptability.
What problems should be paid attention to before making production plans and production schedules?
1, delivery date, quantity and customer of the order.
2, the daily or weekly production capacity of each process, bottleneck process.
3. The technological structure of products with order demand, whether there are bottlenecks or special machinery and equipment, and how long the production cycle is.
The ultimate goal of the plan is to ensure that all orders can be delivered on time, so if there are special process requirements, bottlenecks, long production cycle and early delivery, these are the first things you should consider in your plan.
What are the measures to control the production schedule?
First, the inventory should be changed.
Generally speaking, inventory is not only raw materials or finished products, but also exists in the state of work in progress in most cases. Work-in-process mainly refers to all blanks and parts in the process from the purchase of raw materials and parts by enterprises to the production and then to the storage of the produced products.
Second, maintenance
Equipment failure is the main cause of insufficient production in many enterprises, and it is also a widely used means in production schedule control. However, most enterprises think that the probability of equipment failure is random and unpredictable, and they often do not pay attention to equipment maintenance because of the busy production tasks, but focus on the emergency repair after the failure. In fact, this is very unwise. In the process of controlling the production schedule, the production supervisor should focus on the maintenance of equipment to reduce the failure rate of equipment and shorten the repair time of equipment. Only in this way can we constantly change.
Third, arrange the operation time reasonably.
Lost time cannot be recovered. Generally speaking, enterprises can only make up for the lost time by working overtime, but they have to pay overtime wages to the operators. However, if the equipment operates in three shifts, there is no possibility of overtime and losses can be avoided. Therefore, in the usual production process, the production supervisor should learn to arrange the working hours of workers reasonably.
Fourth, cultivate all-round workers.
Cultivating versatile workers is one of the indispensable topics in the work of production supervisors, which is due to:
(1) When the operators operating key equipment are not available, sending other operators to take the place of this post can avoid the situation of production stop or output decline.
(2) In the case of multi-variety, small quantity or production according to orders, the program design of the assembly line should be changed frequently, which requires the operator to have versatile skills to meet the needs of changing models.
③ Adapt to the change of production plan. In order to adapt to the fierce competition in the market, enterprises often change their production plans according to some requirements of customers, which requires operators to have a variety of skills.
Pmc production plan, schedule control? What is the basis for making a production plan, how to control it, what anomalies will occur and how to deal with them? Make and control the production plan according to the known production conditions. Production conditions include material supply and preparation, device capacity, staffing, working hours, unit capacity, etc.
Abnormal situations often appear in all links, but the quality anomalies caused by the process can not be accurately estimated by PMC.
How to make and revise JIT production plan? (1) Make JIT production plan
Under JIT production mode, what is really to be implemented is the monthly production plan for the next three months. The production plans for the nth month, the nth+1month and the nth+2nd month are made in the nth-1month. The production plan of the nth month calculated in this way is a definite plan, and the plans of the nth+1and the nth+2nd month are only considered as "default" plans. When the nth month becomes the nth month, appropriate modifications will be made and finalized.
Revision of JIT production plan
As we all know, the market is changing very fast now. Some customers may push orders, some customers may request to change the type of products to be purchased, and some customers may cancel orders. However, under the traditional push production mode, it is impossible to respond to the above market changes in time. Therefore, enterprises should adopt the pull production mode and revise the production plan at any time according to the increase or decrease of orders to meet the market demand.
How to make a production plan for an enterprise should be done step by step.
1, collecting production information (people, machines, materials, methods and environment)
2. Arrange the order priority.
3. Prepare the completion date of each order according to the production information (if the completion date of the order cannot be reached, we should find a way to solve it while maintaining the standard cost, and the order that cannot be reached should be postponed or shipped in batches)
4. According to the production statistics tracking plan, timely find and eliminate abnormal situations (insufficient production progress, low qualified rate of finished products, high failure rate of mechanical equipment, too many employees leaving their posts, unskilled production technology, etc.). ).
What is the production plan? How to make it? Production plan is a plan made by a unit or individual to complete a certain stage of production tasks. How to make the minimum project principle of production plan: arrange production plan with the least number of projects. If there are too many projects in the production plan, it is difficult to predict and manage. Therefore, according to different manufacturing environments, we should choose different levels of product structure to make production plans. In the manufacturing and assembly process of product structure level, the number of products (or components) selected is minimized to improve management review and control. Principle of independence and concreteness: list practical and concrete constructable projects, not some task groups or planned list projects. These products can be broken down into identifiable parts or components. The production plan should list the actual items to be purchased or manufactured, not the plan.