1、 Introduction to production and material control
What is production and material control (PMC)?
PMC stands for the abbreviated form of product material control, which means production and material control, abbreviated as production control. It is usually divided into two parts:
PC: production control or production control. Its main function is production planning and production schedule control. MC: material control (commonly known as material control). Its main functions are material planning, purchase requisition, material scheduling, material control (bad material control and normal material in and out control), etc.
What should good production and material control management do? 1. Establish and formulate a complete production and material control operation system (i.e. the overall operation procedure from sales to shipment).
2. Forecast and make reasonable short, medium and long-term sales plans.
3. Carry out detailed analysis on the production capacity load in advance, and establish perfect data.
4. Complete monthly production plan (total production schedule) and weekly production plan in the early stage of production
5. Cooperate with production plan to achieve good material control.
6. Follow up, communicate and coordinate the production progress and material progress in time.
What are the phenomena easily caused by poor production control
1. Due to the unscheduled production or unscheduled materials, the material schedule often fails to keep up with the schedule, resulting in frequent downtime.
2. In the production process, a meal of hunger and a meal of satiety are often stopped for materials. When materials arrive, the delivery period naturally shortens, and the production time is insufficient. Only overtime work is needed to catch up with the goods. As a result, sometimes they starve and sometimes die.
3. The inaccuracy of material plan or the poor control of materials, the failure to link up the semi-finished products or raw materials, the failure to come or a large number of non due materials, resulting in a large number of stacked materials and semi-finished products in the warehouse, the production is naturally not smooth.
4. The production plan only plays a formal role and is divorced from the actual production. The plan is one set and the production is another set. The production plan does not play a role at all and only has a form.
5. Inaccurate sales forecast or capacity analysis, no reasonable arrangement for capacity, no space left, weak motivation of production plan, frequent change of production plan, more emergency orders, and the implementation of production plan has become a bubble.
6. The poor coordination of planning, production and material progress affects the delivery time and reduces the reputation of the company.
7. The production is often disordered and the quality is out of control, resulting in frequent rework, which in turn affects the implementation of the production plan and creates a vicious circle.
The role of production and material control department 1. Be able to coordinate a more reasonable annual, quarterly and monthly sales plan for the orders received by the sales department.
2. Appropriate restrictions can be imposed on the sales department to change the production plan at will, add orders in an emergency or cancel orders at will.
3. According to the capacity load analysis data, we can make a reasonable and perfect production plan, prepare for the ups and downs of production orders and changes of production plans, and reserve "backup procedures".
4. Be able to accurately control the production progress and supervise the material progress of the material control personnel.
5. When the production progress is backward, it can timely and actively discuss with relevant departments about countermeasures, negotiate solutions, and take actions to remedy.
Five modules of production and material control 1. Capacity load assessment 2. Order review 3. Production plan 4. Material plan
5. Delivery plan
2、 Capacity evaluation, order review
1.0 capacity assessment
As a manufacturing enterprise, how to evaluate its own production capacity, i.e., "production capacity" has a full and objective understanding, so as to facilitate the coordination of people, materials and machines in the formulation of actual production plans. If the workload exceeds the 'production capacity', the situation will be that there is quantity but not quality, which is difficult to meet the customer's requirements for quality and function; it will also cause the increase of work in process and inventory. If too little 'production capacity' can not meet the customer's order demand, it will also cause cost waste. Therefore, the production capacity needs to be analyzed and balanced according to the current situation. See the following illustration for interpretation.
1.2 application description production capacity measurement is simply the number of products that can be produced by the production equipment within a certain period of time (usually weekly or monthly). Normal capacity is the average usage of production equipment in the past, and the maximum capacity is the maximum output of production equipment, which is the full load output. It is a theoretical reference value and a reference for planned capacity. As the planned capacity, the relevant subjective and objective factors have not been taken into account in the calculation of working hours. Therefore, the standard measure is effective capacity. It is used in the production of machines and equipment, taking into account the factors such as maintenance, waiting for materials and the defective products repaired in the production process, so as to serve as the standard (performance index) benchmark for the assessment of the production department.
The quality and quantity processes and trends reflected in its production capacity are exactly close to the 'flexible management', that is to say, under the condition of fully estimating people, materials and machines, we can get the adjustment, flexibility and flexible control of production plan and actual completion.
1.3 operation tips
For the capacity analysis and measurement of enterprises that use and involve more production equipment, attention should be paid to:
★ the manufacturing process and bearing capacity of the production machine of the enterprise are mainly the full load of machine operation. At the same time, the lead time of material preparation should be reserved, that is, the time preparation for material control, purchase and warehousing.
★ the total standard time of products, and the standard time of each manufacturing process is the effective capacity standard and human load capacity; that is, the total working hours and the number of personnel calculated according to the planned output and standard working hours.
★ for the production configuration, environmental site and bearing capacity, in case of urgent order or rush to work to "flush the lights", the shift system or overtime method shall be used after assessing the bearing degree of the machine under the safe operation, and the number of employees shall be increased to improve the machine utilization rate in terms of manpower.
2.0 order review 1. External review: review according to market forecast, customer integrity, order quantity, profit, collection cycle, etc. --- the purpose of review is to receive or not to receive;
2. Internal review: review the order delivery time, product specification, quality requirements and other aspects according to the company's current production personnel, machinery and equipment, production process, purchase cycle, etc. -------- reply to the customer's order delivery time, and ensure delivery according to the reply delivery time;
2.1 purpose of order review: 1. Evaluate abnormity, advance abnormity and prepare data; 2. Ensure the effective completion of customer order to meet customer needs;
2.2 application scope of order review 1. All customer orders 2. Review of order changes
2.3 order review department business department (business department), PMC department, product technology department (Engineering Department), quality assurance department, production department, purchasing department, general manager
2.4 consequences of out of control order review 1. Out of control order review will cause production / purchase errors; 2. Out of control order review will cause production plan delay; 3. Out of control order review will cause order delay; 4. Out of control order review will cause production chaos
2.5 out of control performance of order review
1. Order review has gone through the field; 2. Order change at will (1) production is not coordinated as a whole, and orders are inserted at will; 2) order change at will (internal reasons, customer reasons)
2.6 order classification 1. Regular order: the order that has been produced and repeatedly placed by the customer. (regular order review: the planner and the commercial department shall have a simple communication, and both parties shall negotiate and determine the delivery date)
2. Unconventional order: an order that has not been produced or that the customer has specific requirements. (new order, emergency order, change order)
3、 Production plan 3.0 production plan production plan refers to the plan for the three elements "delivery date, quality and cost" to meet the customer's requirements on the one hand; on the other hand, it enables the enterprise to obtain appropriate benefits, and for the exact preparation, distribution and use of the three elements "materials, personnel, machinery and equipment" of production.
[classification by plan level / action level]
Master production plan (MPS)
Production plan (MPS)
——This classification is common and practical (especially in companies with physical factories). No matter the primary or secondary production plan (or primary MPS or secondary MPS), its performance entity is the scheduling of an operation. And select the process which can best reflect the operation and control of the company as the embodiment of its MPS (Master MPS). In general manufacturing industry, the final assembly process is adopted as its MPS (main MPS).
3.2 how to arrange the schedule? 1. The time required for product design (some of which have been designed in advance need not be considered). 2. Time required from receiving the order to material analysis. 3. Time required to purchase materials. 4. Time required for material transportation. 5. The time required for incoming inspection of materials (including the time waiting for handling). 6. Time required for production. 7. Time from completion of finished products to preparation for shipment
3.3 what elements does the production plan include? All production planning systems have some common elements. Whether the production planning system is arranged manually or designed by computer, it must include:
Type and name of work department (workshop, line, group, drawing and machine).
According to the manufacturing sequence from parts to finished products.
The time it takes to make a product.
3.4 the production plan shall meet the following conditions: 1. The plan shall be the result of comprehensive consideration of all relevant factors; 2. It must be a production plan with capacity basis; 3. The thickness of the plan must conform to the content of the activity; 4. The plan must be issued in a necessary period.
3.5 what characteristics should a complete production planning system have? 1. It should be simple and clear, which can be understood and used by top management and grass-roots management.
2. The goal can be achieved through appropriate efforts. The goal is neither too loose nor too strict. The schedule has enough time to cope with one
5.3 task content 1. The salesman / Merchandiser shall confirm the delivery date and quantity of the products required by the customer according to the production notice and order review form; confirm the actual quantity and inventory quantity of the products already produced according to the finished product delivery control form (determined according to the daily finished product inventory daily report); issue the delivery notice after confirmation, indicating the order number, product name, specification The delivery time and quantity shall be reported to the sales accountant of the financial department for confirmation.
2. According to the order contract, the sales accountant of the financial department reviews the authenticity of the delivery items; according to the customer payment record and the company's credit regulations for the customer, reviews whether the customer's payment meets the requirements; if it meets the requirements, it shall sign the delivery notice and transfer it to the domestic trade / foreign trade operator; if it does not meet the requirements, it shall sign the comments and return it to the domestic trade / foreign trade business Member.
3. The domestic trade / foreign trade clerk shall submit the delivery notice confirmed by the sales accountant to the general manager for approval. If it is not approved, it shall be returned to the domestic trade / foreign trade clerk for rearrangement and operation. If it is approved, it shall be submitted to the domestic trade / foreign trade clerk for form distribution.
4. The domestic trade / foreign trade salesman shall make two copies of the delivery notice approved by the general manager, one copy shall be submitted to the PMC Manager and one copy shall be submitted to the finished product warehouse supervisor of the PMC department, and the original notice shall be kept by himself.
5. PMC Manager shall immediately arrange PC specialist to follow up the warehousing of finished products after receiving the delivery notice, and the finished product warehouse supervisor shall check the warehousing of finished products after receiving the delivery notice, and immediately organize the warehouse keeper to prepare goods.
6. According to the product name, specification, quantity, etc. specified in the delivery notice, the warehouse keeper shall count and prepare the goods and pull the products into the storage area. If the product quantity is abnormal, the warehouse keeper shall immediately notify the domestic trade / foreign trade salesman. If there is no abnormal, the warehouse keeper shall immediately issue the release note to the finished product warehouse supervisor for review.
7. The warehouse keeper will load the goods according to the "release strip" approved by the finished product warehouse supervisor, and then hand it over to the transport driver. The driver will hand over the "release strip" to the administrative security for registration and release.
8. After the delivery of finished products, the warehouse keeper of finished products will establish the delivery list on the computer according to the details of the delivery notice and the actual delivery volume. After the preparation of the delivery list, the price of the settlement department will be known through computer sharing, and a copy will be printed and submitted to the supervisor and the manager for review and filing.
9. After pricing the delivery list, the settlement department shall submit it to the sales accountant of the financial department for confirmation. After confirmation, the sales accountant shall transfer it to the general manager for approval. After approval, the general manager shall transfer it to the financial deposit.
5.4 relevant forms 1. Production notice 2. Order review form 3. Finished product delivery control form 4. Delivery list 5. Release note 6. Daily report of finished product inventory
This article comes from the network, which is organized and released by the heat transfer press, rubber sole roughing machine, Youli shoes machine Co., Ltd. hotline: 13592760466
