Unit PRODUCTION PLANNING

Course
Engineering management
Study-unit Code
A002966
Curriculum
In all curricula
Teacher
Lorenzo Tiacci
Teachers
  • Lorenzo Tiacci
Hours
  • 72 ore - Lorenzo Tiacci
CFU
8
Course Regulation
Coorte 2022
Offered
2024/25
Learning activities
Caratterizzante
Area
Ingegneria gestionale
Academic discipline
ING-IND/17
Type of study-unit
Obbligatorio (Required)
Type of learning activities
Attività formativa monodisciplinare
Language of instruction
English
Contents
Introduction to production systems
Basic concepts for the management of production systems
Managing items with stationary and independent demand
Managing items with dependent demand
Just-in-time, Lean Production and Six Sigma.
Reference texts
ADOPTED:
Tiacci, L., "Gestione delle Scorte - Modelli matematici e loro applicazione - 2A EDIZIONE", Lulu, 2021. (acquistabile al link: http://www.lulu.com/spotlight/LorenzoTiacci)
Sianesi, A., "La Gestione del Sistema di Produzione", ETAS, 2011.
SUGGESTED:
Nahmias, S., "Production and Operations Analysis" - Sixth Ed. - McGrawHill, 2013
Silver, E.A., Pyke, D.F., Thoms, D.J., "Inventory and Production Management in Supply Chains" - Fourth Ed. - CRC Press 2017.
Silver, E.A., Pyke, D.F., Peterson, R., "Inventory Management and Production Planning and Scheduling" - Third Ed. - WILEY 1998.
Schiraldi, M., "La gestione delle scorte", Esselibri, 2007.
Chopra, S. , Meindl, P., "Supply Chain Management", Pearson, 2007.
Educational objectives
The course objective is to provide basic knowledge for the management of a production system as a whole, in order to optimize its performances in terms of costs reduction and service level fulfillment.

The main knowledge gained will be:

definitions and classifications of production processes and production systems
knowledge related to productivity and efficiency measures
theoretical knowledge on materials management, such as inventory control policies for items with independent demand
theoretical knowledge related to material with dependent demand, such as heuristic for lot sizing, forecasting, and basic concepts of Material Requirement Planning
Basic knowledge of Just in Time and Lean Production
The main skills are:
application of forecasting techniques on historical data for the calculation of future requirements
Ability to develop the Sales and Operations Plan (S & OP)
Ability to develop Master Production Schedule (MPS)
Ability to optimize order quantities and reorder points
Ability to optimize the time interval between orders and the order-up-to levels
Prerequisites
In order to understand and to apply most of the techniques described in the course it is essential the knowledge of the following topics:
- Integral, indefinite integrals, multi-variable functions, maximum and minimum bounded
- Probability density functions, basic concepts of statistics.
It is also important to have succesfully taken an exam about Facilities Planning.
Teaching methods
The course is organized as follows:
- Theoretical lessons on all topics of the program
- Classroom exercises consisiting in solving practical problems
The exercises are held during class time, and immediately follow the theoretical lesson to which they refer
Other information
Attendance is not compulsory but strongly adviced.
Learning verification modality
The exam consists of a written exam and an oral exam.
The written exam consists in an exercise in which the student has to solve a problem related to subject as demand forecasting, inventory control, MRP. The exercise aim is to determine the ability to correctly apply the theoretical knowledge, the understanding of the issues proposed, and the concentration ability needed to perform correctly the calculation needed to solve the problem. The test duration is approximately 1h 30m
The oral exam consists of 3 questions designed to ascertain the level of knowledge and understanding of the issues on theoretical and methodological aspects of the program. The duration of the test is about 30 min.
Extended program
Introduction to Production Systems
Definitions of production system and production process
The classification of the production processes and production systems
Classification of "products”
Classification based on the management methods adopted (push and pull approaches)
Classification based on technological processes
Classification of assembly based on work organization
Classification based on the lay out
The classifications of synthesis
Performance measurement
Classification models for performances and operating conditions
The measurement of the operating conditions
The operating statuses of a resource
The availability of a productive resource
production potentiality and production rate
The measure of use, productivity and yield
The measure of use, productivity and yield
The measure of the OEE
Production costs
Models for demand forecasting
Correlation for market demand forecasting
Extrapolation
The components of the demand
Possible demand models
Intervals and periods
The static method
Self-adaptive methods
Measures of errors
Tuning of self-adaptive forecasting methods
Monitoring and Controlling Forecasts
General concepts related to stocks
Classification of stock types
Classification of stocks based on the state of transformation
Stocks classification based on the performed functions
The relevant costs for decisions
Stock keeping costs
Replenishment costs
Stock out costs
Models for items with constant and deterministic demand
Quantity of reorder with approximately constant question
The economic order quantity (EOQ)
Sensitivity analysis
Quantity discounts
The economic production quantity (EPQ)
Considering deterministic lead times
Models for items with time-varying and deterministic demand
The Wagner-Whitin method
The Silver-Meal heuristic
The “least unit cost” (LUC) heuristic
The "part period balancing" (PPB) heuristic
The "lot for lot" (L4L) method
Fixed quantity and fixed period methods
Models for items with probabilistic demand
Definitions and notation
CONTINUOUS REVIEW POLICY (s, Q) (order point, order quantity)
Strengths and weaknesses
Common derivation
Setting the (s, Q) policy for individual items
Allocation of a certain amount of safety stock (in value) among several items
Selecting the design criteria
The exchange curves
PERIODIC REVIEW POLICY (R, S) (review period, order up to level)
Strengths and weaknesses
Common derivation
Equivalence formulas for (R,S) policy and policy (s,Q)
Setting the (R, S) policy for individual items
The choice of reorder period in the case of multiple items
Variability in the replenishment lead time
The connection between demand forecasting and inventory control
How to estimate the average demand
How to estimate the standard deviation of errors during the lead time
The "requirement management" techniques
The general framework of requirement management systems
From stock management systems to requirement-based management systems
General concepts related to requirement management systems
Demand planning and forecasting
Aggregate sales planning and capacity management
The sales and operations planning process
The relevant costs in medium-term planning
The Sales and Operations Plan (S&OP)
The Master Production Schedule (MPS)
The logical flow from the S&OP to the MPS
The level and chase approaches for the formulation of the MPS
The Rough Cut Capacity Plan
The models for the formulation of the MPS
Requirements planning (MRP)
The basic concepts of MRP systems
Short term scheduling notes
Introduction and classification of scheduling problems
Examples of solutions for job allocation to machines
Examples of techniques for the formulation of the operational pian
Just In Time, Lean Production and Six Sigma to improve the production system
Introduction to Quality Management and Operations improvement methodologies
The Toyota Production System
The 14 Principles of Toyota Way
From the principles to the implementation of the TPS
The Kaizen approach and continuous improvement
Techniques and tools for implementing TPS
Data Collection Sheet
Histograms
The "5 WHYs"
Cause-and-effect diagrams
Control Charts
The 5Ss
Poka Yoke
Leveling of the Master Production Schedule (Heijunka)
Pull management of production and suppliers: the Kanban system
Six Sigma
The key principles of Six Sigma
Statistical foundations of Six Sigma methodology
The organizational structure and roles of Six Sigma
Obiettivi Agenda 2030 per lo sviluppo sostenibile
Questo insegnamento concorre alla realizzazione degli obiettivi ONU dell'Agenda 2030 per lo Sviluppo Sostenibile
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