Achieve Manufacturing Excellence with PPC

Achieve Manufacturing Excellence with PPC

In the manufacturing business, timely order fulfillment is paramount. It’s important to maximize your business resources while adhering to processes and timelines.

In this blog, we’ll explore how Production, Planning and Control (PPC) can boost your business efficiency and productivity with ERP software. Production, planning and control are the backbone of a manufacturing business. It entails planning and organizing resources to meet the planned production schedules, and controlling manufacturing activities to ensure optimal resource utilization for timely delivery of orders.

By effectively managing resources, schedules, and workflows, PPC streamlines operations, minimizes waste, and enhances productivity as a whole.

What Is The Role Of Production Planning And Control In Manufacturing?

Optimization of Resources
Capital, manpower, machinery, materials and time are the valuable resources of a company. PPC ensures that resources are used efficiently to achieve the set production objectives and, at the same time, avoid waste as well as costs.

Inventory Management
PPC plays a crucial role in managing inventory levels by forecasting demand, determining reorder points and optimizing stock levels, thus avoiding carrying costs.

Capacity Planning
By analyzing production capacity and demand forecasts, PPC helps determine the optimal production levels to meet customer requirements without overloading or underutilizing resources.

Quality Control
For manufacturers, a product’s quality holds supreme importance. By implementing quality control measures at various stages of the production process, companies can ensure that products meet specified quality standards and comply with regulatory requirements.

PPC systems need to be flexible and adaptable to accommodate changes in production requirements, such as fluctuations in demand, supply chain disruptions or changes in product specifications.

Phases of Production Planning and Control (PPC)

  1. Forecasting: Accurate forecasting helps in determining production levels and inventory requirements. Forecasting is the initial phase that involves predicting future demand for products based on historical data, market trends, customer orders and other relevant factors.
  2. Order Entry: Once demand is forecasted, orders from customers are entered into the system. This involves recording order details, specifications, quantities and delivery schedules.
  3. Master Production Scheduling: The MPS sets the production schedule for finished goods over a specific time. In this phase, the overall production plan is developed, considering factors such as available capacity, inventory levels and demand forecasts.
  4. Material Requirement Planning: Based on the MPS, material requirements are planned and calculated for production. By taking into account lead times, inventory levels, and order quantities, it generates purchase orders and production schedules to ensure timely availability of materials.
  5. Capacity Planning: Capacity planning ensures that production levels align with available resources and helps in identifying potential bottlenecks or constraints. By assessing resources such as equipment, machinery, labor and workspace, the production capacity can be planned more efficiently.
  6. Quality Control: Throughout the production process, quality control measures are implemented to ensure that products meet specified quality standards. ERP quality control involves inspections, testing, and corrective actions to prevent defects and maintain product quality.
  7. Dispatching: Dispatching involves issuing work orders and instructions to the shop floor based on the production schedule. It includes assigning tasks to specific work centers, allocating resources, and coordinating activities to ensure the smooth execution of production plans.
  8. Inspection: Ensuring adherence to planned production processes is crucial for maintaining quality standards. To achieve this, a thorough inspection of each step in the production process is necessary. Any deviation from the established quality parameters requires immediate action, including halting production to prevent further losses. Additionally, addressing any errors made by workers is essential to upholding product quality and preventing the recurrence of issues.

How does ERP software work in collaboration with PPC ?

ERP software streamlines the operations of manufacturing businesses by integrating data from various departments for production planning and control (PPC). It forecasts demand, schedules production and manages resources efficiently. Real-time monitoring enables quick decision-making, while quality control measures ensure adherence to standards.

ERP software solutions facilitate shop floor control, inventory management and reporting for continuous improvement. Integration of ERP with PPC optimizes operations, enhances efficiency and enables agile responses to market dynamics.

Coming up with a strategic plan for production planning and control leads to achieving manufacturing excellence. Through the utilization of advanced ERP software from ERP solutions providers such as SourcePro, manufacturing companies can streamline their processes, foster expansion, and outshine competitors within today’s rapidly changing marketplaces.

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