How to do a good print production plan and solve the factory chaos
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Balanced sales planning and production planning
1. Production-oriented enterprises can be divided into inventory production type and order production type enterprises according to the relationship between production and sales. The former emphasizes production according to the established plan, and the sales department makes sales estimates according to products, market conditions and sales methods, and accordingly Set the minimum finished product inventory and carry out series production; the latter is to arrange the production after receiving the customer's order.
2. Formulation of the plan
(1) Sales plan
In reality, there are many factories that do not have an annual sales plan beforehand, or have an annual plan. The sales department accepts orders that are not more than the original plan, or the original plan is too different, resulting in the entire factory including production. Management, quality control, materials, production and personnel departments are in a hurry, and they are struggling to cope. As a result, the delivery time is lengthened, production cannot be improved, and production efficiency and product quality are greatly affected.
At this time, business executives often blame the production department. In fact, in the case of stable production factors, most of the chaos comes from the lack of a reliable sales plan, which leads to the inability to make a perfect production plan. Control is naturally challenged. Therefore, regardless of the inventory production type or the order production type, the sales department should conduct market surveys every year and make estimates, taking into account factors such as customer category, product category, ordering quantity, delivery time, etc. The formulation of the annual sales plan for each month is the basis for the normal development of production.
(2) Monthly plan
Around the 20th of each month, the sales department proposes the next month's sales (shipping) plan. This shipping plan should consider the order status and the actual load status of the production department. Before the end of the month, the sales department, technical department, supply department, and production. The department reviews the next-month sales (shipment) plan proposed by the sales department. The sales department finally determines a relatively detailed plan. The technical department determines the technology research and development (adjustment) plan, the supply department determines the procurement plan, and the production management department proposes the next-month production plan. Similarly, considering the order status and the production capacity of the production department, the sales department, the production management department, and the technical department conduct “production and sales coordination” to determine the production tasks. In addition, the production department should be allowed to set aside a certain period of time (generally around 5%). Additional emergency orders are available.
In addition to the annual and monthly plans, the sales and production departments should make weekly plans and daily plans to ensure that the planned execution cycle is as short as possible so that there is a finer control over the overall situation, and problems can be remedied in time.
3, work assignment
After the production plan is determined, the production department should use the team as the unit to schedule the production plan of the team. The same product and the production process should be connected in time. The flow of the semi-finished products will be smooth. The buffer between the team and the team will be kept to avoid the connection. Not on or too much.
4. Preparation before preparation of production plan
(1) Whether the materials are complete;
(2) Familiar with the company's products and understand the product processing procedures;
(3) Ways of using materials;
(4) understand market demand;
(5) Understand the dynamics of employees and the level of materials in the normal operation of the machine;
(6) Effective tracking and control of production schedule;
(7) The production instructions must be carefully and accurately ordered, and should not be underestimated or leaked;
(8) Information needs timely feedback and follow-up;
(9) Appropriate consideration of abnormal conditions;
(10) Understand the production capacity of the workshop;
(11) Manage independent needs;
(12) Quality and quality control;
(13) Under normal circumstances, the schedule cannot be too tight to consider the situation of inserting an urgent order;
(14) Understand the products, related process flow, and bottleneck process: the first process is first purchased;
(15) Understand the performance of materials;
(16) The procurement cycle of the materials and the arrival of the materials are followed up;
(17) Reasonably deploy personnel;
(18) Contact the supply and storage department and personnel to ensure the supply of materials;
(19) Contact technical support with engineering and technical departments;
(20) Develop and review the corresponding series of plans: such as product development plan, production operation sequencing plan, personnel plan, capacity plan and load plan, inventory plan, shipment plan, material plan, outsourcing plan, etc.
Schedule
1. Schedule (order production type)
From the sales department to the order to the production department to complete the production and shipping process planning a schedule, from which you can get:
(1) How the entire process is connected.
(2) How to simplify the whole process, how to shorten the time and strive for orders.
(3) Develop a standard time for each stage of the process, which can be:
A. The standard delivery lead time for the order received by the sales department.
B. Production management is the basis for production planning.
C. Pointer for progress control of each team.
The order production schedule usually uses the reverse scheduling method, that is, after the delivery date is determined, the production plan, material plan, and purchase plan schedule are carefully arranged.
2, people tend to focus on the delivery department, in fact, production time is only a part of the total time, production time is the most difficult to compress, we should be from product design time, procurement time, In terms of delivery time, etc., try to shorten the time, design products, purchase materials, and produce products with mutual complementarity. Which products have large market demand and long life cycle, you can use inventory production. For those products with small demand and short life cycle, order production can be used.
Production schedule management
1. Production schedule management content
From the schedule benchmark process, we can see that the output of a product needs to go through many departments and personnel. Each department and personnel should have their own progress and control and control, unlike some companies that regard production progress as manufacturing. The responsibility of the department, while ignoring the progress management, the progress management can be summarized into the following aspects:
(1) Transactional progress
After receiving the customer's order, go to the time control of material analysis, ordering, etc.
(2) Procurement progress
The purchased materials and parts should be provided with standard purchase time and strictly controlled.
(3) Inspection progress
The time for completion of acceptance after the material enters the plant should be controlled.
(4) Outreach progress
Entrust the management of the processing and production time schedule of the external unit.
(5) Production progress
It is controlled by both the manufacturing department and production management.
2. Progress management method
The more common schedule control methods are:
(1) Batch control method
Production plans are written in batches and used as a basis for schedule management. This method is suitable for inventory production products.
(2) Order Control Act
This method is suitable for order production. Each order is numbered (sometimes orders are large, batch, instalment, or the order can be opened to issue a manufacturing order), which is the most common in general enterprises.
3. Basic process of production schedule management
(1) The sales department signs the sales order in conjunction with the capacity load feedback from the production management personnel.
(2) The sales department will arrange the sales plan (the total number and the order number, product, quantity, delivery date) after consultation with the production management department.
(3) The production management department shall arrange the production plan for the season, month and week according to the production capacity and sales plan of the factory.
(4) Purchasing department determines the procurement feeding plan according to the production plan and material inventory, and negotiates with the supplier in time to determine the feeding plan.
(5) The purchasing personnel verify and follow the progress of the feed.
(6) The warehousing personnel prepare the required materials in advance, and report the feedback to the purchasing personnel in advance.
(7) The production department controls the production capacity and controls the production schedule according to the production plan. The problems are promptly returned to the production management personnel and controlled and adjusted in time.