Systems for Planning and Control in Manufacturing

Contents......Page 5
Series Preface......Page 11
Foreword......Page 13
Introduction......Page 15
Case study: Automation means efficiency?......Page 17
1.1 Overview......Page 21
1.2 Hierarchy of management control......Page 23
1.3 Classification of manufacturing organizations......Page 24
1.4 Strategy......Page 25
1.5 Developing a strategy......Page 26
1.7 Process choice......Page 27
1.8 Facilities organization......Page 28
1.9 Determining optimal layouts......Page 30
1.9.1 Cross and relationship charts......Page 31
1.10 New facilities......Page 33
1.11.1 Functional layout......Page 34
1.11.3 Development of GT......Page 35
1.11.4 Prerequisites for GT......Page 37
1.12.2 Basic definitions......Page 39
1.12.3 Largest candidate approach......Page 40
1.12.4 Ranked positional weight approach......Page 42
1.12.5 General principles......Page 43
2.2 General accounting principles......Page 45
2.3.1 Single entry system......Page 46
2.3.2 Double entry system......Page 47
2.4.1 Basic principles......Page 48
2.4.2 The effect of loans......Page 49
2.4.3 The effect of assets......Page 50
2.4.5 Dangers and limitations......Page 51
3.2.1 Costing terminology......Page 53
3.2.2 Overhead recovery......Page 54
3.3 Setting prices......Page 56
3.4 Budgeting......Page 57
3.5.1 Overview......Page 58
3.5.2 Simple methods......Page 59
3.5.4 Net present value......Page 60
4.1 Overview......Page 64
4.2 Sequential engineering......Page 65
4.3 Concurrent engineering......Page 66
4.5 QFD structure......Page 67
4.5.1 Detailed HOQ matrix......Page 68
4.5.3 QFD summary......Page 70
4.6.2 FMEA example......Page 71
Exercises - Manufacturing systems......Page 73
Exercises - Financial accounting......Page 75
Exercises - Management accounting......Page 76
Exercises - Management of design......Page 78
Case study:\r The system made of matchsticks......Page 79
5.1 Overview......Page 83
5.2 Evolution of IT/IS systems in business......Page 84
5.3 The commercial environment......Page 85
5.4.1 General principles......Page 86
5.4.2 Help - development by users......Page 87
5.4.3 Buy - packaged solutions......Page 88
5.4.4 Make - bespoke development......Page 89
5.5.1 General......Page 90
5.5.3 Symptoms of poor systems......Page 91
5.6 Justification for IT/IS systems......Page 92
5.7 System development methodologies......Page 93
5.9 Personnel......Page 95
5.10 SSADM overview......Page 96
5.11 Systems and analysis......Page 97
6.3.1 Sources of information......Page 99
6.3.2 Reporting......Page 101
6.6 Flowcharts......Page 102
6.7.1 Overview and graphical conventions......Page 103
6.7.2 Example of a DFD......Page 104
6.7.3 Decomposition of DFDs......Page 105
6.9.1 Overview......Page 107
6.10 Limitations of the classical approach......Page 110
6.11.1 Overview......Page 111
7.2 Approaches to data storage......Page 114
7.3 Entity-relationship modelling......Page 116
7.4.1 Obligatory......Page 117
7.4.3 Recursive relationships......Page 118
7.5.2 Logical errors......Page 119
7.6 Application of E-R models......Page 121
8.3 Indexes......Page 122
8.4 Basic database development......Page 123
8.5 Database management systems......Page 124
8.6 Database tables......Page 125
8.7 Normalization and determinants......Page 126
8.8 E-R models and databases......Page 127
8.10 Use of the database......Page 128
8.13 Changeover tasks......Page 129
8.15 Post-implementation tasks......Page 130
9.2 Nature of change......Page 131
9.3.1 Business processes vs functions......Page 132
9.4.1 Hierarchical structures......Page 134
9.4.3 Matrix organization......Page 135
Exercises - Introduction to systems analysis......Page 138
Exercises - Systems design......Page 141
Exercises - Data analysis......Page 142
Exercises - Databases......Page 143
Exercises - Business process re-engineering......Page 144
Case study: Decisions, decisions......Page 145
10.1.1 Qualitative and quantitative analysis......Page 147
10.2.2 Addition of probabilities......Page 149
10.2.4 Statistically dependent events......Page 150
10.3.2 The normal distribution......Page 152
10.3.3 Standard statistical formula......Page 154
11.2 Intuitive forecasting......Page 155
11.3.2 Exponential smoothing......Page 156
11.3.3 Second-order smoothing......Page 158
11.4.2 Regression analysis......Page 159
11.4.3 Correlation coefficients......Page 162
11.6 Improving forecast accuracy......Page 163
12.2 The objective function......Page 166
12.3 Basic optimization concepts......Page 167
12.4.1 Basic concepts......Page 169
12.4.2 Graphical method......Page 170
12.4.4 Sensitivity analysis......Page 172
13.2.1 Overview......Page 175
13.2.2 Decision-making situations......Page 176
13.2.4 Value of perfect information......Page 177
13.2.5 Decision making under uncertainty......Page 178
13.3 Decision-making example......Page 179
14.1 Overview......Page 181
14.3 Simulation methodology......Page 182
14.4 Continuous simulation......Page 183
14.5 Discrete event simulation (DES)......Page 184
14.5.1 Deterministic simulation......Page 185
14.5.2 Simulation methods......Page 186
14.5.3 Stochastic simulation......Page 187
14.6 Limitations of simulation......Page 188
15.2.1 Definition of terms......Page 189
15.2.2 Network diagrams......Page 190
15.3.1 Definitions......Page 192
15.4.1 Overview......Page 193
15.4.2 Analysis method......Page 194
15.6 Project management practice......Page 197
Exercises - Probability and statistics......Page 199
Exercises - Forecasting......Page 200
Exercises - Optimization......Page 202
Exercises - Evaluating alternatives......Page 203
Exercises - Project management......Page 205
Case study: The red sticker system......Page 207
16.2 Basic definitions Ò items and BOMs......Page 211
16.3 Order models of control......Page 213
16.4 Basic reorder point theory......Page 214
16.5 ROP limitations......Page 215
16.6 Use of safety stock......Page 216
16.7 EOQ theory......Page 219
16.9.1 Dependent and independent demand......Page 221
16.9.2 MRP mechanics......Page 222
16.9.3 MRP calculation......Page 223
17.2 Closed-loop control......Page 226
17.3.1 Overview......Page 228
17.3.3 Monitoring of plans......Page 229
17.3.4 Planner action lists......Page 230
17.4.1 MRPII packages......Page 231
17.4.2 MRPII data structures......Page 233
17.4.3 Master files......Page 234
17.5 Development of ERP from MRPII......Page 235
18.1 Overview......Page 238
18.2 Reasons to master schedule......Page 239
18.3 MPS stability......Page 240
18.4 MPS mechanics......Page 241
18.5 Two level MPS techniques......Page 245
18.6 Management aspects of MPS......Page 247
19.2 Limitations of MRPII......Page 249
19.3 Infinite vs finite capacity scheduling......Page 250
19.3.1 Infinite capacity scheduling......Page 251
19.3.3 Finite capacity scheduling......Page 253
19.4 Schedule optimization......Page 255
19.4.1 JohnsonÌs algorithm......Page 256
19.5.2 Sequencing rules......Page 257
19.6 Short interval scheduling......Page 259
19.7 Problems of finite capacity scheduling......Page 260
19.8.1 Shop floor feedback......Page 261
19.9.1 Overall concept......Page 262
19.9.2 CRP vs RCCP......Page 263
19.11 OPT principles......Page 264
19.12 OPT scheduling logic......Page 266
20.2 Japanese manufacturing practice......Page 273
20.3 Kanban......Page 274
20.3.1 Other kanban techniques......Page 276
20.4 ERP extensions to support kanban......Page 278
20.6 Influence of JIT......Page 279
20.7.2 Influence of JIT......Page 282
20.7.3 Customer-supplier communication......Page 283
21.2.1 SPC theory......Page 285
21.3.2 Quality - cost trade-off......Page 288
21.5 Certification......Page 290
22.1 Overview......Page 295
22.2 Overall equipment effectiveness......Page 296
22.3.2 Traditional approach to maintenance......Page 297
22.3.3 Use of CMMS......Page 298
22.4.2 5S approach......Page 300
22.4.3 SMED approach......Page 301
Exercises - Open-loop control......Page 303
Exercises - Closed-loop MRP......Page 304
Exercises - Master production scheduling......Page 305
Exercises - Finite and infinite capacity scheduling......Page 306
Exercises - Quality management......Page 308
Exercises - Plant management......Page 309
References......Page 310