Unit 1008: Operations Planning and Control

1. Introduction to Operations Planning and Control

• Definition and scope
• Role in managing resources, processes, and activities
• Aligning operations with organizational objectives
• Importance of efficiency and effectiveness

2. Forecasting Techniques

• Purpose and importance of forecasting
• Qualitative methods
  • Expert opinion
  • Delphi method
  • Market research
• Quantitative methods
  • Time series analysis (moving averages, exponential smoothing)
  • Causal models (regression analysis)
• Selecting appropriate forecasting methods
• Accuracy measurement and error analysis (MAD, MSE, MAPE)

3. Capacity Planning

• Definition and objectives
• Types of capacity (design, effective, actual)
• Capacity measurement and evaluation
• Identifying bottlenecks and constraints
• Strategies to adjust capacity
  • Capacity expansion
  • Capacity reduction
  • Demand management
• Tools and techniques for capacity planning

4. Inventory Management

• Importance of inventory control
• Types of inventory (raw materials, work-in-progress, finished goods)
• Inventory costs (holding, ordering, shortage)
• Inventory control models
  • Economic Order Quantity (EOQ)
  • Reorder point calculation
  • Safety stock determination
• Just-in-Time (JIT) inventory approach
• Inventory tracking systems (ABC analysis, RFID, barcoding)

5. Production Scheduling

• Objectives and challenges
• Scheduling techniques
  • Gantt charts
  • Critical Path Method (CPM)
  • Program Evaluation and Review Technique (PERT)
• Prioritization rules (FIFO, LIFO, EDD)
• Resource allocation and utilization
• Reducing lead times and bottlenecks

6. Quality Control and Assurance

• Definitions and differences between quality control and assurance
• Quality standards and frameworks (ISO, Total Quality Management)
• Statistical Process Control (SPC)
  • Control charts
  • Process capability
• Six Sigma methodology
• Continuous improvement tools (PDCA cycle, Kaizen)
• Root cause analysis and corrective actions

7. Lean Operations

• Introduction to lean principles
• Types of waste (TIMWOOD: Transport, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects)
• Lean tools and techniques
  • Just-in-Time (JIT) production
  • Value Stream Mapping
  • 5S workplace organization
  • Kanban systems
• Benefits and challenges of lean implementation

8. Supply Chain Management

• Overview of supply chain components
• Roles of suppliers, manufacturers, distributors, and retailers
• Integration and coordination mechanisms
• Demand and supply synchronization
• Inventory and logistics management
• Information flow and technology in SCM
• Risk management in supply chains

9. Performance Measurement and KPIs

• Importance of performance measurement
• Types of KPIs in operations planning and control
  • Efficiency metrics (e.g., capacity utilization, throughput)
  • Effectiveness metrics (e.g., on-time delivery, defect rates)
  • Financial metrics (e.g., cost per unit, inventory turnover)
• Setting targets and benchmarks
• Data collection and analysis
• Using KPIs for continuous improvement