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WIP Flow: A Card system for Production Planning and Control

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IBRAHIM MOHAMMED, PMP
IBRAHIM MOHAMMED, PMP

The document summarizes Card Based Production Planning & Control (PPC) System. It describes the system's components including a loop of cards between the shop floor and planning office and card display boards. It explains how the system works through phases like order entry, process planning, job release and execution. The system aims to provide realistic delivery times for customers by monitoring current workload and throughput. It also demonstrates the system with a sample of jobs and order entry. The document outlines the system's fundamentals including work breakdown structure, routing operations, shop design and training. It describes what the card system does and does not do in production planning and control.

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Card Based Production Planning &Control (PPC) System Presented by [Ibrahim Mohammed]
Problem Statement Q: How can we quote realistic delivery times for Customer Order? Ans: A system to keep stock and estimate current workload and shop through-put A system to sequence product transformation A system to monitor and control product transformation
PPC Options Kanban 5s Lean MRP TPS JIT Six Sigma OPT POLCA
How To Choose?
Workload Control (WLC) Concept Based on creating predictable and short through-put times for each critical work station predictable throughput times are important for a good timing of order releases, for quoting realistic delivery times, and for good timing of capacity adjustments.
SYSTEM COMPONENTS 1. Loop of Cards between the Shop Floor and the Planning Office 2. Card Display Boards 3. Order Guiding Form 4. Support Staff
How it Works (Phases) Order Entry Phase Process Planning Phase Job Release Phase Job Execution Phase (Shop Floor) Monitoring and Control
How it Works (Process Flow) .
Demo (Today: Jan-01) Jobs Simulation: Mickey Sculpture Oryx Sculpture Tweety Bird Cage AWR Farmhouse Pot Type 4 KZ Doha Airplane Turbine Uniflora Pot Type 1 VM Accessories Risers LMG Feature Wall Cutouts Frit Panels
Demo (Order Entry: Easter Eggs) .
Fundamentals (Axioms) Pillar 1: WBS Customer orders (products) can be broken down into sub-components that can be routed independently, and produced as a set of basic operations Pillar 2: Routing/Operations Sequence Each subcomponent can be designed as a sequence of simple, repetitive operations Pillar 3: Shop Design/Structure The shop floor is designed to integrate human labor and machine Shop is divided into work centers i.e. where and when an operation must be performed Shop operations are categorized by work centers Job dispatching rules/Job processing rules are established Pillar 4: Training Training in skills and teamwork
Pillar 1: WBS .
Pillar 2: Routing/Operations Sequence Cutting Room Carving Modeling (Application of Clay) Modeling (Detailing of Clay) Metal Fabrication (Steel Framework) Mold Making GRP (Casting) GRP (Tooling/Stamping) Metal Fabrication (Base Plate) Surface preparation Renderring JOB ROUTING Each Job Route = 1 Job Card 1 Job Stage Each Job Card = Complete List of Operation at a Job Stage
Pillar 2: Routing/Operations Sequence ID WORK CENTRE 1 Cutting Room 2 Carving 3 Modeling 4 Modeling 8 GRP (Tooling) 9 Metal Fabrication 10 Surface Prep. 11 Artistry Apply Top Coat paint on sculpture and base plate 12 Paint Finishing 6 7 GRP (casting) Apply Epoxy Primer to base Plate Paint base plate Attach metal baseplate to feet of sculpture, as in drawing Wash out excess wax, carry out light sanding of smooth areas, apply primer make rendering of the sculpture as per reference image provided and approved pantone colors Mold Making5 Metal Fabrication Fabricate Metal Framing for Sculpture Fabricate metal baseplate for sculpture Demarcate the model with forex cards according to the number of parts of the mold required Make rubber mold with hard backing of each part of the After curing is completed, release the mold by removing the model, then degrease the mold by washing with soap and pressurised water Cast the product in 2 layer GRP + Metel Frame (Armature) After curing is complete, release product from mold Trim out excess material on the product along the line of DETAILS OF OPERATIONS Cut EPS model of product to scale of 1:1 Assemble and carve out shape of product, by hand Mold clay on the EPS model Imprint body details of sculpture onto the clay molded on the EPS model Apply wax over the entire surface area of the model
Pillar 3: Shop Design/Structure WORK CENTER FOREMAN TEAM LEADER 1 TEAM MEMBER 1 TEAM MEMBER 2 TEAM MEMBER 3 TEAM MEMBER 4 TEAM LEADER 2 TEAM MEMBER 1 TEAM MEMBER 2 TEAM MEMBER 3 TEAM MEMBER 4 Team Structure (unit of organization) Operations Categories (basis of categorization)
Pillar 4: Training Supervision Leadership Teamwork
Resource Requirement Process Planning Phase Process Planner Job Release Phase Release Planner Shop Floor WIP-Inventory Controller Monitoring and Control Phase Planning Data Officer (Data Control and Analysis) ***most importantly: PLANNING ROOM
What the Card System Does Reduces uncertainty in the control decision by using feedback loops that update the current situation on the shop floor in real time Coordinate the flow of products through the system Coordinate the flow of products in accordance with the availability of transforming resources Reduce waiting waste i.e. free up capacity
What the card System Does Not Do Does not ensure quality- ensuring quality is the job of Total Quality Mgt. (TQM) or Six Sigma Does not improve efficiency of material transformation process- this is the job of design and engineering Does not improve efficiency of an operation itself- this is the job of motion studies, improved job design, or improved product design Does not make unreliable machines reliable- this is the job of Total Productive Maintenance (TPM) Does not reduce transportation waste Does not solve the problem of multiple points of control Does not solve the problem of Jaldi Jaldi Does not solve the problem of cashflow/material approval
Scaling Up Integration of QC Function Integration of Sales/Marketing Function Integration of Materials Inventory/Store Automation

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WIP Flow: A Card system for Production Planning and Control

  • 1. Card Based Production Planning &Control (PPC) System Presented by [Ibrahim Mohammed]
  • 2. Problem Statement Q: How can we quote realistic delivery times for Customer Order? Ans: A system to keep stock and estimate current workload and shop through-put A system to sequence product transformation A system to monitor and control product transformation
  • 5. Workload Control (WLC) Concept Based on creating predictable and short through-put times for each critical work station predictable throughput times are important for a good timing of order releases, for quoting realistic delivery times, and for good timing of capacity adjustments.
  • 6. SYSTEM COMPONENTS 1. Loop of Cards between the Shop Floor and the Planning Office 2. Card Display Boards 3. Order Guiding Form 4. Support Staff
  • 7. How it Works (Phases) Order Entry Phase Process Planning Phase Job Release Phase Job Execution Phase (Shop Floor) Monitoring and Control
  • 8. How it Works (Process Flow) .
  • 9. Demo (Today: Jan-01) Jobs Simulation: Mickey Sculpture Oryx Sculpture Tweety Bird Cage AWR Farmhouse Pot Type 4 KZ Doha Airplane Turbine Uniflora Pot Type 1 VM Accessories Risers LMG Feature Wall Cutouts Frit Panels
  • 10. Demo (Order Entry: Easter Eggs) .
  • 11. Fundamentals (Axioms) Pillar 1: WBS Customer orders (products) can be broken down into sub-components that can be routed independently, and produced as a set of basic operations Pillar 2: Routing/Operations Sequence Each subcomponent can be designed as a sequence of simple, repetitive operations Pillar 3: Shop Design/Structure The shop floor is designed to integrate human labor and machine Shop is divided into work centers i.e. where and when an operation must be performed Shop operations are categorized by work centers Job dispatching rules/Job processing rules are established Pillar 4: Training Training in skills and teamwork
  • 13. Pillar 2: Routing/Operations Sequence Cutting Room Carving Modeling (Application of Clay) Modeling (Detailing of Clay) Metal Fabrication (Steel Framework) Mold Making GRP (Casting) GRP (Tooling/Stamping) Metal Fabrication (Base Plate) Surface preparation Renderring JOB ROUTING Each Job Route = 1 Job Card 1 Job Stage Each Job Card = Complete List of Operation at a Job Stage
  • 14. Pillar 2: Routing/Operations Sequence ID WORK CENTRE 1 Cutting Room 2 Carving 3 Modeling 4 Modeling 8 GRP (Tooling) 9 Metal Fabrication 10 Surface Prep. 11 Artistry Apply Top Coat paint on sculpture and base plate 12 Paint Finishing 6 7 GRP (casting) Apply Epoxy Primer to base Plate Paint base plate Attach metal baseplate to feet of sculpture, as in drawing Wash out excess wax, carry out light sanding of smooth areas, apply primer make rendering of the sculpture as per reference image provided and approved pantone colors Mold Making5 Metal Fabrication Fabricate Metal Framing for Sculpture Fabricate metal baseplate for sculpture Demarcate the model with forex cards according to the number of parts of the mold required Make rubber mold with hard backing of each part of the After curing is completed, release the mold by removing the model, then degrease the mold by washing with soap and pressurised water Cast the product in 2 layer GRP + Metel Frame (Armature) After curing is complete, release product from mold Trim out excess material on the product along the line of DETAILS OF OPERATIONS Cut EPS model of product to scale of 1:1 Assemble and carve out shape of product, by hand Mold clay on the EPS model Imprint body details of sculpture onto the clay molded on the EPS model Apply wax over the entire surface area of the model
  • 15. Pillar 3: Shop Design/Structure WORK CENTER FOREMAN TEAM LEADER 1 TEAM MEMBER 1 TEAM MEMBER 2 TEAM MEMBER 3 TEAM MEMBER 4 TEAM LEADER 2 TEAM MEMBER 1 TEAM MEMBER 2 TEAM MEMBER 3 TEAM MEMBER 4 Team Structure (unit of organization) Operations Categories (basis of categorization)
  • 17. Resource Requirement Process Planning Phase Process Planner Job Release Phase Release Planner Shop Floor WIP-Inventory Controller Monitoring and Control Phase Planning Data Officer (Data Control and Analysis) ***most importantly: PLANNING ROOM
  • 18. What the Card System Does Reduces uncertainty in the control decision by using feedback loops that update the current situation on the shop floor in real time Coordinate the flow of products through the system Coordinate the flow of products in accordance with the availability of transforming resources Reduce waiting waste i.e. free up capacity
  • 19. What the card System Does Not Do Does not ensure quality- ensuring quality is the job of Total Quality Mgt. (TQM) or Six Sigma Does not improve efficiency of material transformation process- this is the job of design and engineering Does not improve efficiency of an operation itself- this is the job of motion studies, improved job design, or improved product design Does not make unreliable machines reliable- this is the job of Total Productive Maintenance (TPM) Does not reduce transportation waste Does not solve the problem of multiple points of control Does not solve the problem of Jaldi Jaldi Does not solve the problem of cashflow/material approval
  • 20. Scaling Up Integration of QC Function Integration of Sales/Marketing Function Integration of Materials Inventory/Store Automation