Teaching Plan
FACULTY OF MANUFACTURING ENGINEERING
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
PRODUCTION PLANNING AND CONTROL
BMFP 4513
SEMESTER 2
SESSION 2010/2011
1.0 Learning Outcomes
At the end of this course, student should be able to;
a. Explain the strategic implications of the production planning and control
(PPC) models and techniques for managing production systems. Also
includes Lean Production and JIT.
b. Describe the elements of planning and control in an overall framework
for Enterprise Resource Planning (ERP), supply chain management
systems and the function of management information systems in the
current industries.
c. Apply production planning techniques such as aggregate planning,
scheduling, assembly line balancing (ALB) and material requirement
planning (MRP).
d. Work and communicate effectively as a team to deliver the project
result.
2.0
Synopsis
This course covers the principles and practices, tools and techniques of
production planning and control which are the dynamic backbone in basic
production operation. This course consists of operations planning, order
scheduling, supply chain, and shop floor control viewed within the framework
of Material Requirement Planning (MRP) and Enterprise Resource Planning
(ERP) systems.
The students will also be shown engineering concept involving production
lean with improvement analysis method such as Lean Six Sigma. In addition,
the students will be exposed to management information system within the
dynamic environment.
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
1/9
3.0 Practical Application
Students are assumed to be familiar with basic statistics, operation
research, and operation management. Students will be required to
perform one (1) individual assignment and one (1) group assignment/ case
study and one (1) group presentation that expose production planning and
control techniques which most of industries apply. There will be a project
that also will be based on industrial problems which will enhance their
understanding in the topics of the chapter they are learning.
The assignment /case study will cover necessary chapters that will enable
the students to have comprehensive understanding on PPC tools and
techniques. Based on one (1) group assignment, the student will discuss
about the application on this subject. Students will be grouped into 3-4
students per group for the group assignment and group presentation in
order to expose the students to team work. Presentation for project is
necessary, so that each team may share the knowledge with others.
4.0 References
5.0
No.
1
2
3
4
5
6
7
1.
Nahmias, S. (2008) Production Operations Analysis. Mc Graw Hill/ Irwin.
6th Edition
2.
Vollman, T.E., Berry, W.L. Whyback, D.C. and Jacobs, F.R. (2005).
Manufacturing Planning and Control for Supply Chain Management. 5 th
Edition. Mc Graw Hill/Irwin
3.
Stephen, N.C. (2005). Fundamentals of production Planning and Control.
Prentice Hall.
4.
Krawjewski J.L. and Ritzman P. L., (2002), Operations Management:
Processes Value Chains. 7th Edition, Prentice Hall International Series.
5.
Seng,Y.Kam (2003), Industrial Management, 3rd Edition Prentice Hall.
Course Implementations
Session
Lecture
Tutorial
Case Study
Project & Presentation
Quiz
Test
Final exam
TOTAL
GRAND TOTAL
Hrs
3
1
1
2
0.5
1.5
3
Official contact hours = 62.5 hrs
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
Freq
14
10
2
1
4
1
1
Official
Contact SLT Hrs
42
2
10
2
2
2
2
3
2
1
1.5
3
3
4
62.5
128.5
Freq
14
10
2
1
4
1
1
Student
Learning
Time (SLT)
28
20
4
3
4
3
4
66
Expected student self-learning = 66 hrs
2/9
6.0
Course Evaluations
NO.
COURSE WORK
1
Case study – 1
 Individual activity (report)
2
Case study -2
 Group activity (report)
3
Project (Case Study-2) Presentation x 1
 Group project basis presentation (3 ~ 4 persons/group)
4
Quiz x 4
 Test on student’s knowledge and understanding about the
relevant topic
5
Test x 1 (1.5 hr)
 Test on student’s knowledge and understanding about the
relevant topic.
Final
Exam (3 hrs)
6
Understanding, Applications, Problem Solving and Decision
Making.
TOTAL
7.0
PERCENTAGE, %
7.5
7.5
10
@2.5 (10)
15
50
100
Method of Assessment
COMPONENT
Tests / Quizzes
Project & Presentation
Assignment and Case
Study
KNOWLEDGE
X
X
COMPETENCY
X
X
ATTITUDE
X
X
X
X
X
COMMUNICATION
X
8.0 Detail Syllabus and Teaching Plan
Week
1
2
Session
Contents
20 -24
FEB’12
1.0 INTRODUCTION TO PRODUCTION
PLANNING AND CONTROL
1.1 Production Systems
1.2 Production process objectives
1.3 Functions in production systems
27 FEB- 2
MARCH’12
2.0 COMPETITIVENESS, STRATEGY, AND
PRODUCTIVITY
2.1 Competitiveness
2.2 Strategy
2.3 Productivity
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
Remarks
Course Outline
Briefing
Tutorial 1
3/9
Week
3
4
Date
5-9
MARCH’12
12 – 16
MARCH’12
Contents
3.0 AGGREGATE PLANNING
3.1 Overview of aggregate planning
3.2 Demand capacity option
3.3 Aggregate units of production
3.4 Technique for aggregate planning.
• Spreadsheet methods
• Linear programming methods.
3.0 AGGREGATE PLANNING (con’t)
• Disaggregation
3.5 Costs in aggregate planning
3.6 Solving aggregate planning
problems
3.7 The linear decision rule
3.8 Modeling management behavior
4.0
5
19 – 23
MARCH’12
4.0
6
7
8
26 – 30
MARCH’12
SCHEDULING
4.1 Introduction
4.2 Job Shop Scheduling Terminology
4.3 Sequencing Rules
• FCFS
• SPT
• EDD
• CR
SCHEDULING (con’t)
4.4 Sequencing Theory for a Single
Machine
4.5 Sequencing Theory for Multiple
Machines
4.6 Assembly Line Balancing
4.7 Advanced Topics for Operations
scheduling
2-6
APR’12
5.0 MATERIAL REQUIREMENTS PLANNING
5.1 Background and fundamentals
concepts
5.2 Dependent Inventory Model
Requirement
• Master Production Schedule
• Bills of Material
• Accurate Inventory Records
• Lead Times for components
5.3 MRP Structure
5.4 Potential MRP challenges
9 - 13
APR’12
SEMESTER BREAK
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
Remarks
Tutorial 2
&
Quiz 1
[Presentation 1]
Tutorial 3
[Presentation 2]
Tutorial 4
&
Case Study 1
[Presentation 3]
Tutorial 5
&
Quiz 2
[Presentation 4]
Tutorial 6
TEST 1
[Presentation 5]
4/9
Week
Session
Contents
6.0
9
16 – 20
APR’12
6.1
6.2
6.3
6.4
10
11
23 – 27
APR’12
30 APR 4 MAY’12
Remarks
ENTERPRISE REQUIREMENTS
PLANNING (ERP)
Background and fundamentals
concepts
Advantages and Disadvantages of
ERP Systems
ERP in the Service Sector
Potential and Challenges
7.0
SUPPLY CHAIN
7.1 What is SCM
7.2 Information in SCM
7.3 Formulations
7.4 Distribution and Warehouse
Management
7.0
7.5
7.6
7.7
[Presentation 7]
SUPPLY CHAIN (con’t)
Transportation methods
Design and solutions
Global supply chain
Tutorial 9
[Presentation 8]
7 - 11
MAY’12
13
14 - 18
MAY’12
9.0 MIS
9.1 General system design and
selection
9.2 General implementation
approaches
9.3 SAP
9.4 BAAN IV
14
21 - 25
MAY’12
15
28 MAY – 1
JUNE’12
10.0
REVIEW (The
materials – PPC)
Tutorial 10
&
&
Quiz 4
[Presentation 9]
[Presentation 10]
[Presentation 11]
[Presentation 12]
[Presentation 13]
concept
10.1 Manufacturing Process
The Next Frontier
[Presentation 6]
Tutorial 8
&
Quiz 3
8.0 LEAN
8.1 Lean production and JIT
•
Fundamentals and concepts
•
Some impacts on capacity
8.2 Pull System
8.3 Kanban
8.4 Using kanban system for process
improvement
8.5 Master scheduling and lean
production
8.6 Six Sigma fundamental concepts
(DMAIC)
12
Tutorial 7
&
PROJECT
and
Control:
10.0 REVIEW (The concept and materials
– PPC) (cont’)
16
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
FINAL EXAM
5/9
8.0 Matrix of Learning Outcomes:
PROGRAM OUTCOMES
No
Learning Outcome
1.
Explain the strategic
implications of the production
planning and control (PPC)
models and techniques for
managing production systems.
Also includes Lean Production
and JIT.
2
3
4.
Describe the elements of
planning and control in an
overall framework for
Enterprise Resource Planning
(ERP), supply chain
management systems and the
function of management
information systems in the
current industries.
Apply production planning
techniques such as aggregate
planning, scheduling,
assembly line balancing (ALB)
and material requirement
planning (MRP).
Work and communicate
effectively as a team to
deliver the project result.
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
P0
1
P0
2
X
P0
3
P0
5
P0
6
P0
7
P0
8
P0
9
P0
10
X
X
X
P0
4
X
X
X
X
X
X
X
X
7/9
P0
11
Delivery
Assessment
Lecture
Case study
Group
activity
Assignment
Tutorial
Quiz, Test,
Final Exam,
Project
Report, Case
Study Report
Lecture
Case study
Assignment
Tutorial
Quiz, Test,
Final Exam,
Project
Report, Case
Study Report
Lecture
Case study
Assignment
Lab activity
Test,
Final Exam,
Project
Report
Lecture
Case study
Assignment
Lab activity
Case study
Project
Report
Presentation
KPI
60% Student
Achieve
Grade C
Above
CS
Learning Outcomes for BMFP 4513
1
1
Explain the strategic implications of the production planning and
control (PPC) models and techniques for managing production
systems. Also includes Lean Production and JIT.
x
2
Describe the elements of planning and control in an overall
framework for Enterprise Resource Planning (ERP), supply chain
management systems and the function of management information
systems in the current industries.
x
x
x
3
Apply production planning techniques such as aggregate planning,
scheduling, assembly line balancing (ALB) and material requirement
planning (MRP).
x
x
4
Work and communicate effectively as a team to deliver the project
result.
x
x
2
3
4
CTPS
5
6
7
8
1
2
3
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
4
x
TS
5
6
7
x
1
2
3
4
5
x
x
x
x
x
x
x
x
x
x
BMFP 4513
LL
Learning Outcomes for BMFP 4512
1
2
x
x
1
Explain the strategic implications of the production planning and control
(PPC) models and techniques for managing production systems. Also
includes Lean Production and JIT.
2
Describe the elements of planning and control in an overall framework for
Enterprise Resource Planning (ERP), supply chain management systems
and the function of management information systems in the current
industries.
3
Apply production planning techniques such as aggregate planning,
scheduling, assembly line balancing (ALB) and material requirement
planning (MRP).
x
4
Work and communicate effectively as a team to deliver the project result.
x
ES
3
1
2
3
4
1
2
x
LS
3
1
2
x
x
x
x
x
x
x
BMFP 4513
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
EM
8/9
x
3
4
LO KURSUS VERSUS TAKSONOMI
PSIKOMOTOR
KOGNITIF
Learning Outcomes for BMFP
4513
1
2
3
1
Explain the strategic implications of
the production planning and control
(PPC) models and techniques for
managing production systems. Also
includes Lean Production and JIT.
x
x
2
Describe the elements of planning
and control in an overall framework
for Enterprise Resource Planning
(ERP), supply chain management
systems and the function of
management information systems in
the current industries.
x
3
Apply production planning
techniques such as aggregate
planning, scheduling, assembly line
balancing (ALB) and material
requirement planning (MRP).
x
x
x
4
Work and communicate effectively
as a team to deliver the project
result.
x
x
x
4
5
6
1
2
x
x
3
4
x
x
6
7
1
2
3
x
x
x
4
x
x
x
x
x
x
x
x
x
x
x
x
x
BMFP 4513
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
5
AFEKTIF
9/9
x
5
APPROVAL
Prepared by ;
Approved by ;
………………………….
Name
: Hasoloan Haery
Post
:
Stamp
:
………………………………..
Dean/Deputy Dean(Academic)/Head of Dept.
Stamp :
Date
Date : __________________
: _________________
TEACHING PLAN IMPLEMENTATION STATUS
(MID-SEMESTER BREAK)
Comments :
Check by ;
………………………………..
Dean/Deputy Dean(Academic)/Head of Dept.
Stamp :
Date : _______________
TEACHING PLAN IMPLEMENTATION STATUS
(16th WEEK OF SEMESTER)
Comments :
Check by ;
………………………………..
Dean/Deputy Dean(Academic)/Head of Dept.
Stamp :
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka
Date : _______________
10/9