Manufacturing and Production Planning and Control (MPPC)

This DIXONTECH course delivers a comprehensive understanding of Manufacturing and Production Planning and Control (MPPC), focusing on aligning production systems with strategic business goals. It equips participants with the knowledge to optimize production processes, manage resources effectively, and ensure continuous improvement in operations. The program integrates Lean, JustInTime (JIT), and ERPbased planning techniques to enhance manufacturing efficiency and productivity.

TRAINING TOPICS

• Fundamentals of manufacturing systems and production control
• Master production scheduling (MPS) and material requirements planning (MRP)
• Capacity planning and resource optimization
• Production workflow and process design
• Inventory control and demand management
• Lean manufacturing and JIT principles
• ERP systems and digital production planning
• Quality control and performance monitoring
• Best practices in operations and continuous improvement

BY THE END OF THIS TRAINING COURSE, DELEGATES WILL BE ABLE TO:

• Plan and control production systems efficiently
• Develop accurate production schedules
• Integrate MRP and ERP planning tools
• Manage capacity and workflow constraints
• Apply Lean and JIT methodologies
• Reduce costs through process optimization
• Monitor performance using key production metrics
• Enhance operational flexibility and responsiveness

TRAINING IS TAILORED TO:

• Production and operations managers
• Manufacturing engineers and supervisors
• Supply chain and logistics coordinators
• Industrial and process engineers
• Planning and scheduling specialists
• Quality and continuous improvement officers
• ERP and manufacturing systems analysts
• Plant and factory management professionals

TRAINING METHODOLOGY:

This DIXONTECH training combines theoretical concepts with practical applications using case studies, simulations, and realworld manufacturing examples. Participants engage in interactive workshops on production scheduling, process optimization, and datadriven decisionmaking using ERP tools. The methodology emphasizes teamwork, lean techniques, and practical implementation of planning and control strategies.

DAY 1:

INTRODUCTION TO MANUFACTURING SYSTEMS AND PRODUCTION PLANNING

• Overview of manufacturing systems and operations strategy
• Objectives and scope of production planning and control
• The role of PPC in manufacturing performance
• Types of production systems: maketostock, maketoorder, engineertoorder
• Key components of the production planning process
• Relationship between planning, scheduling, and control
• Managing information flow in manufacturing systems
• The link between design, operations, and logistics
• Global trends in modern manufacturing management

DAY 2:

DEMAND FORECASTING AND MASTER PRODUCTION SCHEDULING (MPS)

• Forecasting techniques for production planning
• Translating demand into master production schedules
• The role of S&OP in manufacturing synchronization
• Developing feasible MPS for capacity and demand alignment
• Time fences and planning horizons in production control
• Lot sizing and production batching methods
• Balancing demand variability and production efficiency
• Integrating MPS with ERP and MRP systems
• Practical session: building a master production schedule

DAY 3:

MATERIAL REQUIREMENTS PLANNING (MRP) AND INVENTORY CONTROL

• Structure and logic of material requirements planning
• Bill of materials (BOM) and product structure management
• Inventory classification (ABC, VED, FSN)
• Inventory control systems and replenishment models
• Managing safety stock and reorder points
• Lead time and lotsize optimization
• Linking procurement and production plans
• ERP integration and realtime MRP applications
• Workshop: MRP simulation using practical data

DAY 4:

CAPACITY PLANNING, SHOP FLOOR CONTROL, AND PERFORMANCE MANAGEMENT

• Capacity requirements planning (CRP) and resource allocation
• Work center management and bottleneck analysis
• Scheduling techniques: Gantt charts, line balancing, sequencing
• Shop floor data collection and tracking systems
• Measuring production performance (OEE, TEEP, cycle time)
• Managing downtime and throughput efficiency
• Visual management and Kanban control
• Integrating Lean methods with capacity planning
• Case study: optimizing resource utilization in manufacturing

DAY 5:

LEAN MANUFACTURING, JIT, AND DIGITAL TRANSFORMATION IN PRODUCTION CONTROL

• Lean manufacturing principles and waste elimination
• Implementing JIT systems for continuous flow
• Value Stream Mapping (VSM) for process improvement
• Total Quality Management (TQM) and continuous improvement
• Automation and Industry 4.0 applications in production planning
• ERP and MES (Manufacturing Execution Systems) integration
• Data analytics and AI in production forecasting
• Sustainable and agile production management practices
• Final workshop: developing a digital production control strategy