Learning outcomes of the course unit
Knowledge and ability to understand
At the end of the course, the students will acquire the basic knowledge related to the manufacturing planning and control of manufacturing systems.
Students will be able to design the organization of operation and the main processes connected with it, defining the most suitable management policies about the application context. Students will be able to use the knowledge gained to analyse and process numerical data and to support its decisions.
Autonomy of judgement
The student should be able to critically evaluate a production system; or design, choose and implement tools for manufacturing planning and control of production system.
Students will acquire the specific vocabulary relating to production management. It is expected that, by the end of this course, the student can communicate, orally and in writing, also by means of solutions of numerical problems, the main content of the course (for example: MPS, MRP, MRP II and so on.), by commonly used tools in the industry, such as tables, block diagrams or flowcharts.
Students who have attended the course will be able to deepen their knowledge in the field of production management, through the autonomous consultation of specialized texts, scientific or for practitioner’s journals or, even outside of the topics covered tightly to class.
KNOWLEDGE AND ABILITY TO UNDERSTAND
At the end of the course, the student must have acquired the main knowledge related to the classification of production systems and the methods for (i) the calculation of their performance, (ii) the management of industrial production, in terms of programming, planning and control of production.
ABILITY TO APPLY KNOWLEDGE AND UNDERSTANDING:
Students must be able to autonomously plan the organization of operations as a whole, considering the main processes connected to it, defining the most suitable management policies in relation to the application context. The student must be able to use the knowledge acquired to analyse and process numerical data and to support the relevant decision-making choices.
Students must be able to critically evaluate a production system, starting from its classification and analysis of its performance; they must also be able to design, choose and implement a system for planning, programming and controlling production.
The student must acquire the specific vocabulary related to production management. It is expected that, at the end of the course, the student will be able to transmit, orally and in writing, also through the resolution of numerical problems, the main contents of the course (for example: MPS, MRP, MRP II and operational programming, etc.), also through the use of tools commonly used in the field, such as tables, block diagrams or flow diagrams.
Students who have attended the course will be able to deepen their knowledge in the field of production management in general, through independent consultation of specialist texts, scientific or popular journals, even outside the topics covered strictly in class.
No mandatory prerequisite.
Desirable the frequency and the overcoming of class related to the design of production systems, technology and statistics.
No mandatory prerequisites.
Frequency and overcoming of lessons related to the design of production systems, mechanical technology and statistics are desirable.
Course contents summary
Handle the production system requires both direct experience gained in the field, knowledge, tools, techniques and models that have theoretical foundations and that can hardly be achieved on the field.
The aims of this course is to present the main tools, techniques and models that can be used to deal with the processes of manufacturing planning and control systems, including the basic principles of inventory management.
Managing the “production system” requires both direct experience gained in the field and knowledge, models, techniques and tools that have theoretical foundations and that hardly can be taken exclusively from the activity carried out in the field.
This course, starting from a methodical classification of the “production systems” and their performance analysis, aims to present the main models and techniques that can be used to address the processes of planning, programming and control of production including inventory management.
For the updated program of the course, students are referred to the Elly platform.
1. PRODUCTION SYSTEM CLASSIFICATION
Introduction to industrial production management - Long-term planning of production - Aggregate production planning - Production operational planning - Production control – push pull production systems
2. THE PRODUCTION PLAN (PP)
Production Capacity Measurement The Production Plan Setting - Bowman and Megee Models - What if simulation - Resource Requirements Planning (RRP) Module
3. DEMAND FORECASTING TECHNIQUES
Moving average method - Exponential average method; Exponential average trend-correction method - Exponential average seasonality method
4. The Master Production Schedule (MPS)
The Time Cycle Chart - Simple Linear Programming Model - Integral Linear Programming Model - The Rough-Cut Capacity Planning (RCCP)
5. MATERIAL REQUIREMENTS PLANNING (MRP)
MRP Functionality- Problems and Limits in Planning with MRP Systems - MRP Method with Low Level Coding – The Capacity Requirements Planning module
6. INVENTORY MANAGEMENT
Reordering policy reordering policy amounts to constant-interval constant comparison between managing stock in constant amount and interval constant
Scheduling of batch production with the production of a single product-programming of batch production with production of more products-setup time and the concept of critical question
8. BILL OF MATERIAL
BOM explosion and implosion operations-BOM BOM Types Management-configurators
9. SCHEDULING AND PRODUCTION CONTROL
Finite capacity scheduling (Finite Capacity Scheduling (FCS)-loading rules
10. PROJECT MANAGEMENT BASIC PRINCIPLES
Work Breakdown Structure-Gantt-network programming techniques: CPM, PERT-PERT Programming in the presence of limited resources
Part I: INTRODUCTION TO PRODUCTION SYSTEMS
1.1 - Definitions of production system and production process
1.2 - The classifications of the production processes
1.3 - Information on the logistics system
Part II: BASIC CONCEPT FOR THE MANAGEMENT OF PRODUCTION SYSTEMS
2.1 - Introduction
2.2 - Why measure the performance of a production system?
2.3 - Measuring performance within improvement processes: the check-up of the production system
2.4 - Measuring performance and operating conditions: classification models
2.5 - Measurement of operating conditions
2.6 - Measuring internal performance
2.7 - A brief outline of the design of a measuring system
2.9 - Costs for decisions
PART III: PRODUCTION-RELATED MANAGEMENT TECHNIQUES
4.1 - General concepts for stocks
4.2 - Material management
4.3 - Stock management
4.4 - The EOQ-ROP model (economic lot)
4.5 - The fixed interval reordering model
4.6 - The Maximum/Minimum Stock Model
4.7 - Stock efficiency measures
PART IV: NEEDS MANAGEMENT SYSTEMS
5.1 - The general framework of management systems based on needs
5.2 - Planning and forecasting demand
5.3 - Aggregate sales planning and capacity management
5.4 - Needs Planning (MRP)
5.5 - Notes on short term scheduling
ADOPTED BOOK (followed almost exclusively):
De Toni A.F., Panizzolo R., 2018, "Sistemi di gestione della produzione", ISEDI, ISBN: 9788880083825;
Other reference books:
- Jacobs, R.F., Chase, R.B., Grando, A., Sianesi, A., 2020, "Operations management nella produzione e nei servizi", Fourth ed., McGraw Hill, ISBN: 9788838695636
Stevenson W., 2011, "Operations Management", McGraw-Hill Higher Education, ISBN-10: 0073525251; ISBN-13: 978-00735259
1 ) Andrea IANESI, (2011), “La gestione del sistema di produzione”, Editore: Rizzoli Etas, ISBN-10: 8817068063; ISBN-13: 978-8817068062
Alberto F. DE TONI, Roberto PANIZZOLO, (2018) , “Sistemi di gestione della produzione”, Editore: ISEDI; ISBN-10: 8880083821; ISBN-13: 978-8880083825
Frontal lessons (theoretical part of the course), alternating with numerical exercises and cases of study.
The use of computer and telematic supports (recorded videolessons) is required due to the contingent situation in Emilia-Romagna in March 2020.
Theory lessons alternated with numerical exercises and case studies.
Assessment methods and criteria
The exam consists of a written test including both theoretical questions and exercises.
Examination written for both theory and numerical exercises.