The fundamentals of production planning and control / Stephen N. Chapman

Includes bibliographical references and index

Table Of Contents: Preface CHAPTER 1 Overview of Planning and Control 1.1 Manufacturing versus Service Operations 1.2 Customer Influence in Design: Production Environmental Choices 1.3 Process Categories 1.4 Order Winners and Qualifiers 1.5 Business Environment Issues 1.6 Process Analysis and Information Flows 1.7 General Information Flows 1.8 Book Structure Key Terms Summary Discussion Questions References CHAPTER 2 Forecasting Fundamentals 2.1 Fundamental Principles of Forecasting 2.2 Major Categories of Forecasts Qualitative Forecasting Quantitative Forecasting-Causal Quantitative Forecasting-Time Series 2.3 Forecast Errors 2.4 Computer Assistance Key Terms Summary References Discussion Questions Exercises CHAPTER 3 Sales and Operations Planning 3.1 Purpose of Sales and Operations Planning 3.2 General Design of Sales and Operations Planning 3.3 Approaches to Sales and Operations Planning Make-to-Stock View of an S&OP Make-to-Order View of an S&OP 3.4 Strategies for Sales and Operations Planning Some Techniques Trade-off Approaches 3.5 Balancing Resources in Sales and Operations Planning 3.6 Discussion: A Simple Example Chase Level Combination 3.7 Qualitative Issues 3.8 Some Business Environment Issues Key Terms Summary References Discussion Questions Exercises CHAPTER 4 The Master Schedule 4.1 Background and Links to the S&OP 4.2 Master Schedule Horizon 4.3 Time Fences 4.4 Sources of Demand 4.5 Basic Methodology 4.6 Impact of Product Environment 4.7 General Approach to Master Schedule Development 4.8 Available-to-Promise Logic 4.9 Planning Options in an ATO Environment 4.10 The Two-Level Master Schedule 4.11 Some Notes on the Master Scheduling Responsibility 4.12 Demand Management Overview 4.13 Elements of Demand Management Key Terms Summary References Discussion Questions and Problems CHAPTER 5 Inventory Management 5.1 Basic Concepts of Inventory 5.2 Categories of Inventory 5.3 The Basic Inventory Lot Sizing Model-Economic Order Quantity (EOQ) 5.4 Basic Independent Demand Inventory Reorder Models 5.5 Inventory Control Location Approaches for Stockrooms and Warehouses Maintaining Inventory Data Accuracy Obtaining Accurate Inventory Records Key Terms Summary References Discussion Questions and Problems CHAPTER 6 Material Requirements Planning 6.1 Background and Fundamental Concepts The Problem with Reorder Points 6.2 Bills of Material 6.3 The MRP "Explosion" Common Lot Sizing Rules 6.4 Other MRP Issues Generation of Data Updating Information Exception Messages Other Sources of Demand 6.5 Potential MRP Challenges 6.6 Enterprise Resource Planning (ERP) 6.7 Business Environment Issues Key Terms Summary References Discussion Questions and Problems CHAPTER 7 Capacity Management 7.1 Capacity Definitions 7.2 Rough-Cut Capacity Planning 7.3 Capacity Requirements Planning (CRP) 7.4 Input/Output Control (I/O) 7.5 Capacity Measures 7.6 General Approach to Capacity Management Key Terms Summary References Discussion Questions and Problems CHAPTER 8 Production Activity Control 8.1 General PAC Information and Data 8.2 Prioritizing Work Scheduling in MRP and "Pull" Production Environments 8.3 Scheduling 8.4 Loading Infinite Loading Finite Loading 8.5 Corrective Actions Key Terms Summary References Discussion Questions and Problems CHAPTER 9 Lean Production and JIT 9.1 Fundamental Concepts 9.2 Some Impacts on Capacity 9.3 The Pull System The Bicycle Example Revisited The "Down Side" of the Change 9.4 Kanban How It Works 209 Kanban Rules Number of Kanban Cards Kanban Card Alternatives Setting Priorities with Kanban 9.5 Using the Kanban System for Process Improvement 9.6 Master Scheduling and Lean Production 9.7 Are MRP and Kanban Compatible? Key Terms Summary References Discussion Questions CHAPTER 10 Fundamentals of the Theory of Constraints 10.1 Fundamental Principles of the Theory of Constraints 10.2 Understanding and Managing the Constraint 10.3 Improving the Process Using TOC Principles 10.4 Impact on Operations Strategy 10.5 General Types of Constraints Causes 10.6 Logistics and the Theory of Constraints 10.7 Scheduling and the Theory of Constraints 10.8 Multiple Time Buffers 10.9 Control Points and Batches 10.10 Major Steps in Using the Drum-Buffer-Rope Method Key Terms Summary References Discussion Questions CHAPTER 11 "Partnering" Functions: Purchasing and Distribution 11.1 Purchasing Information Issues 11.2 Purchasing Responsibilities for Material Procurement 11.3 Distribution Requirements Planning Basic DRP Structure Key Data Requirements The Bill of Distribution Using the BOD for DRP DRP in a Lean Production "Pull" Environment Key Terms Summary References Discussion Questions and Problems CHAPTER 12 System Integration and Implementation 12.1 General System Design and Selection 12.2 "Push," "Pull," or Somewhere in Between? Hybrid System #1 MRP with Lean Principles Hybrid System #2 Kanban with MRP Planning Hybrid System #3 Using MRP for Capacity and Long Lead Time Items Hybrid System #4 Pull Systems with "Spike" Control Focus on the Point of Customization 12.3 General Implementation Approaches Major Process Steps in Implementation Summary Discussion Questions Index