Curriculum
- 6 Sections
- 30 Lessons
- 2 Days
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- Introduction to PPC5
- 1.1Concepts: PPC Objectives, Key Elements, Planning Horizons
- 1.2Keywords: Push vs Pull, Finite vs Infinite Scheduling, Routing, Loading
- 1.3Situational Focus: Aligning production to fluctuating demand
- 1.4Real-life Insight: Batch-based production failure due to improper sequencing
- 1.5Exercise: Map your current PPC flow vs best-in-class PPC cycle
- Master Production Schedule (MPS)5
- 2.1Concepts: Time Fences, Firm vs Planned Orders, ATP (Available to Promise)
- 2.2Keywords: Make-to-Stock (MTS), Make-to-Order (MTO), FAS (Final Assembly Schedule)
- 2.3Situational Focus: Balancing plant loading for short lead time SKUs
- 2.4Real-life Insight: FMCG plant reducing changeovers via MPS refinement
- 2.5Exercise: Build a basic MPS for a 2-week cycle (Excel-based)
- Material Requirements Planning (MRP)5
- 3.1Concepts: BOM Explosion, Netting Logic, Lot Sizing
- 3.2Keywords: Lead Time Offsets, Pegging, Safety Stocks, Rescheduling Horizon
- 3.3Situational Focus: Stockouts despite high FG inventory – wrong input in MRP
- 3.4Real-life Insight: ERP-MRP misalignment led to raw material bottlenecks
- 3.5Exercise: Simulate an MRP run and track exception messages
- Shop Floor Execution & Control5
- Integration with Procurement & Inventory5
- Advanced Planning – ERP/MES/APS Integration5
- 6.1Concepts: Real-time PPC, Feedback Loops, Rescheduling
- 6.2Keywords: APS, ATP/CTP, Time Bucket Planning, Plant Digital Twin
- 6.3Situational Focus: Real-time plan update in high-mix low-volume setup
- 6.4Real-life Insight: Migration to SAP APO enabled dynamic load balancing
- 6.5Exercise: Real vs Planned Schedule variance workshop
Keywords: Push vs Pull, Finite vs Infinite Scheduling, Routing, Loading
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