An optimized production plan must have the following three characteristics:
1) is conducive to making full use of sales opportunities and meeting market demand;
2) It is beneficial to make full use of profit opportunities and minimize production costs;
3) It is beneficial to make full use of production resources and minimize the idleness and waste of production resources.
On the one hand, the production plan refers to the plan that meets the customer's requirements of "delivery, quality and cost"; On the other hand, it enables enterprises to obtain appropriate benefits and make appropriate plans for the preparation, distribution and use of the three elements of production "materials, personnel and machinery and equipment".
[Edit this paragraph]
Production planning task
1, ensuring delivery date and output;
2. Make the enterprise keep the workload (load) commensurate with its production capacity and the appropriate operating rate;
3, as a benchmark for material procurement;
4. Maintain the inventory of important products or materials at an appropriate level;
5, according to the long-term production plan, make the arrangement of personnel and mechanical equipment supplement.
[Edit this paragraph]
Contents of production plan
1, what to produce-product name, part name;
Example: A kind of cam in auto parts industry, name code: kj908.
2. How much has been produced-quantity or weight;
Because the guest order needs 10000 pieces, the actual production should consider the generation of waste products, and we need to put into production 10500 pieces to ensure the delivery quantity of 10000 pieces.
3. Place of production-departments and units;
Due to the characteristics of the manufacturing industry, it is obvious that we mainly accomplish the indicators in the production department, and the refinement is the processing between the production process teams, including: casting, forging, lathes, milling machines, high-frequency quenching, grinding machines, cleaning and so on.
4. When is it required to be completed? Time limit and delivery date.
If the delivery date of the customer's order is required to be on the 20th of this month, the production and completion of the company should be completed before the 20th to ensure that the customer can receive the goods within the time limit.
[Edit this paragraph]
The purpose of the production plan
1, the basis of material demand planning;
2. The basis of capacity demand plan;
3. Basis for making other relevant plans.
[Edit this paragraph]
Type of production plan
According to different properties, there are various types of production plans, as shown in the following table:
Divide categories into object cycles.
Large-scale planning (long-term) long-term production planning product group 2-3 years season
The annual production plan product group and product category are 1 month.
Mid-term schedule (mid-term) March-June production plan product season, semi-annual week and month.
Month, production plan, products, parts, month, day, etc.
Small plan (short-term) weekly production plan, product category and part category.
Daily production plan, product type, part type, date and time
[Edit this paragraph]
Conditions that the production plan should meet
1, the plan should be the result of comprehensive consideration of all relevant factors;
2. Must have basic production planning ability;
3. The thickness of the plan must conform to the content of the activity;
4, the plan must be issued within the necessary period.
[Edit this paragraph]
Production planning standard
1. Operating plan standard
Operating processing sites;
-The planning standard is gb * * * * where gb refers to enterprises produced in China and * * * refers to industry names); The processing plant can be outsourced or produced in the company, and the specific production unit is the production department.
Type and sequence of operation and treatment;
Examples; Category refers to how many processes a product needs to be processed. For example, the above-mentioned cam processing, the order refers to what to do first, and then what to do according to the completion of cam manufacturing, that is to say, all the processes for producing cams are arranged.
Standard working hours, etc.
2. Standards for process planning and standby capacity planning
Load benchmark of operation and machining process.
Competency benchmarks for operating and processing processes;
-Process planning refers to production and working procedures of production, and standby capacity planning refers to the difference between the production capacity of the enterprise itself and the existing production capacity. For example, the enterprise itself produces 1000 units per day, so now I am producing 800 units, which means that the resources provided by the enterprise can produce up to 200 units. When the total output exceeds 65,438+0,000 pieces, it means that the production capacity of the enterprise is saturated. For example, at this time,
3. Standards for materials and parts planning
Parts composition list and parts list;
Arrange zoning and supply zoning;
Batch size and output rate.
4. Progress standard
Processing and assembly benchmark schedule;
Batch.
5. Standards for preparing inventory plans
Inventory management partition;
Order cycle;
Order point and order quantity;
Safety stock, maximum stock and minimum stock.
The above planning standards should be revised and maintained in time whenever they change!
[Edit this paragraph]
Production planning index
Making production plan indicators is an important content of production plan. In order to effectively and comprehensively guide the production activities of enterprises during the production planning period, the production plan should establish a production index system with four categories of indicators as the main content: product variety, product quality, product output and product output value.
1, product variety index
Product variety index refers to the name, model, specifications and types of products produced by enterprises during the reporting period. It not only reflects the ability of enterprises to meet social needs, but also reflects the professional level and management level of enterprises.
The determination of product variety index should first consider market demand and enterprise strength, and be determined according to the product variety series balance method.
2. Product quality indicators
Product quality index is one of the important indexes to measure the economic situation and technical development level of enterprises. The product quality is controlled by several quality control parameters. The unified regulation of quality parameters has formed quality technical standards, including international standards, national standards, ministerial standards, enterprise standards and internal standards.
3. Product output index
Product output index refers to the physical quantity produced by an enterprise to meet the product quality requirements in a certain period of time. The product output calculated by physical quantity reflects the development level of enterprise production, and is the basis for formulating and checking the output completion, analyzing the proportional relationship between various product quality inspections, balancing product distribution and calculating the production index of physical quantity.
Break-even method and linear programming method are mainly used to determine product indicators.
4. Product output index
Product output value index is an output index expressed in currency, which can comprehensively reflect the achievements of enterprise production and operation activities, so as to compare different industries. According to the specific content and function, it can be divided into three forms: total industrial output value, industrial commodity output value and industrial added value.
[Edit this paragraph]
Master production plan
Production planning is the core of the internal operation of factory management. An excellent factory, its internal management should be around the production plan. Production plan includes monthly plan, weekly plan and daily plan. However, with the use of MRP, "master production planning" has become the core of controlling the internal operation of the factory.
Master production plan
First, the meaning of MPS
Master production planning is a phased method to plan the quantity and delivery date of the final products that an enterprise will produce. Master production plan is a kind of advance production plan, which gives the production quantity of a specific project or product in each planning period. Effective master production plan is the commitment of production to customer demand, which makes full use of enterprise resources, coordinates production and market, and realizes the business objectives expressed in the production plan outline. Master production planning plays a leading role in planning management, which determines the objectives of all subsequent planning and manufacturing activities. In the short term, it will be the basis of material demand planning, parts production planning, ordering priority and short-term capacity demand planning. In the long run, it will be used as the basis for estimating the demand for resources such as production capacity, storage capacity, technical personnel and capital of our factory.
Second, the principle of MPS preparation
Master production planning is to determine what to do according to the enterprise's ability, and to achieve the goal of production planning by arranging production in a balanced way, so that enterprises can improve customer service level, inventory turnover rate and productivity, and update them in time to maintain the feasibility and effectiveness of the plan. There cannot be more materials than available materials and possible capacity in the master production plan. Some basic principles should be followed when making the master production plan.
* The principle of least projects: arrange the master production plan with the least projects. If there are too many items in MPS, it will bring difficulties to forecast and management. Therefore, according to different manufacturing environments, different levels of product structure should be selected to prepare the master production plan. In the manufacturing and assembly process of product structure level, the number of products (or components) selected is minimized to improve management review and control.
* Principle of independence and concreteness: It is necessary to list the actual and concrete constructable projects, not the list items of some project groups or plans. These products can be broken down into identifiable parts or components. MPS should list the actual items to be purchased or manufactured, not the planned list items.
* Key project principle: list the projects that have a significant impact on production capacity, financial indicators or key materials. Projects that have a significant impact on production capacity refer to projects that have a significant impact on the production and assembly process. For example, some large-scale projects, projects that cause capacity bottlenecks or projects that pass through key work centers. For financial indicators, it refers to the projects that are most critical to the company's profit and efficiency. Such as parts with high manufacturing cost, expensive parts, expensive raw materials, high production process cost or special requirements. It also includes those relatively cheap projects, which are the main source of profits for the company. For key materials, it refers to those projects with long delivery time or limited suppliers.
* Principle of comprehensive representation: the planned project should represent the products produced by the enterprise as comprehensively as possible. MPS should cover as many components as possible in the MRP program driven by MPS, and reflect as much information about manufacturing facilities as possible, especially bottleneck resources or key work centers.
* Principle of appropriate allowance: leave appropriate allowance, and consider the time of preventive maintenance of equipment. Preventive maintenance can be arranged as a project in MPS, or the capacity of work center can be reduced according to the time of preventive maintenance.
* Appropriate stability principle: appropriate stability should be maintained during the validity period. After the master production plan is formulated, it should be kept properly stable within the validity period. The practice of arbitrarily changing only according to subjective wishes will destroy the original reasonable and normal priority plan of the system and weaken the planning ability of the system.
Third, the object of the master production plan
The planned object of the master production plan is mainly the finished product after the product series in the production plan is concretized, which is generally called the final project. The so-called "final project" is usually an independent demand part, and its demand exists independently of the demand for other materials. However, due to the different planning scope and sales environment, the final project as the planning object has different meanings.
[Edit this paragraph]
Steps to make a production plan
Production planning must follow four steps.
(1) Collect data and study item by item. Prepare resource information and production information needed for production planning.
(2) Make optimization plans and make overall arrangements. Initially determine the production plan indicators, including the optimization of output indicators, the determination of quality indicators, the reasonable collocation of product varieties, and the reasonable arrangement of product production schedule.
(3) Prepare the draft plan and balance the production plan. Mainly the balance between production indicators and production capacity; Calculate the guarantee degree of the main production equipment and production area of the enterprise to the production task; The balance between production tasks and labor, material supply, energy and production technology preparation capacity; Balance between production indicators and indicators such as capital, cost and profit.
(4) Discuss the revision and finalization for approval. Through comprehensive balance, make appropriate adjustments to the plan and correctly formulate various production indicators. Report to the general manager or the superior competent department for approval.
At the same time, the preparation of production plan should pay attention to the overall situation, efficiency, balance, mass and adaptability.