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ECO CPIM aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company

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aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company

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Table of Contents Session 1—Execution of Operations Manufacturing Planning................................................................................................. 1-9 Manufacturing Planning Hierarchy ........................................................................................................... 1-9

Strategic and Business Planning: Direction- Setting ................................................................ 1-11 Manufacturing Planning and Control: Tactical Operations ...................................................... 1-13 DSP and ECO (Near Term Operations) ...................................................................................... 1-15

Defining Execution and Control Systems ...................................................................... 1-19 Manufacturing Environments .................................................................................................... 1-19 Process Choices ......................................................................................................................... 1-21 Process Layouts.......................................................................................................................... 1-23 Batch Versus Flow Process Implications .................................................................................. 1-25 Push Versus Pull Principles ....................................................................................................... 1-27

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aChain - APICS International Channel Partner - www.achain.com.br Programas CPIM e CSCP abertos e in company i Instructor Guide Version 3.3

Execution and Control Of Operations

Session 2—Scheduling and Authorization MRP-Based Scheduling .................................................................................................. 2-7 MRP-Based Schedule Elements and Inputs.............................................................................. 2-9 Interface With Material and Capacity Requirements Planning ................................................ 2-11 Operations Scheduling Techniques ........................................................................................... 2-13 Other Scheduling Issues ............................................................................................................. 2-31

Theory of Constraints Scheduling.................................................................................. 2-37 Lean Scheduling ...................................................................................................................... 2-41 Overview ...................................................................................................................................... 2-41 Key Elements and Goals of Lean Systems ................................................................................ 2-43 Interface With Manufacturing Planning..................................................................................... 2-45 Production Leveling .................................................................................................................... 2-47

Instructor Guide Version 3.3

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Session 3—Control Of Production Scope and Principles of Operations Control ................................................................. 3-7 Production Activity Control ......................................................................................................... 3-9 Quality Control ............................................................................................................................ 3-11

Production Activity Control: MRP-Based ....................................................................... 3-13 Scheduling and Control Interfaces ............................................................................................ 3-13 PAC in Batch Production and Flow Manufacturing................................................................... 3-15 Control Techniques .................................................................................................................... 3-19

Production Activity Control: Lean Based ....................................................................... 3-35 MRP- Versus Lean-Based Control Systems .............................................................................. Production Control in Lean Systems ......................................................................................... Heijunka ...................................................................................................................................... Takt Time .................................................................................................................................... Pacemaker .................................................................................................................................. The Store ..................................................................................................................................... Kanban System .......................................................................................................................... Transaction Simplification .........................................................................................................

3-35 3-37 3-39 3-41 3-43 3-45 3-47 3-55

Inventory Management Issues ....................................................................................... 3-57 Customer Service, Inventory Investment, and Efficiency......................................................... Inventory Storage ....................................................................................................................... Inventory Identification .............................................................................................................. Inventory Accuracy and Counting .............................................................................................. Accounting Classification ........................................................................................................... Vendor Managed Inventory ........................................................................................................

3-57 3-59 3-63 3-67 3-71 3-73

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Session 4—Control of Costs and Quality Cost Control .................................................................................................................... 4-7 Cost Control Overview ................................................................................................................. 4-9 Product and Period Costs ........................................................................................................... 4-11 Job Order and Process Costing .................................................................................................. 4-13 Absorption and Variable Costing Methods ................................................................................ 4-21 Activity Based Cost Accounting .................................................................................................. 4-23 Cost Variances ............................................................................................................................ 4-25 Cost of Quality ............................................................................................................................. 4-31

Control of Quality ............................................................................................................ 4-35 Quality Planning .......................................................................................................................... 4-37 Types of Quality Problems .......................................................................................................... 4-39 Statistical Quality Control ........................................................................................................... 4-43 Process Capabilty........................................................................................................................ 4-59

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Table of Contents Participant Workbook Page

Session 5—Management and Communication Approaches to Management .......................................................................................... 5-7 Taylor’s Scientific Management ................................................................................................ 5-7 Worker Self-Control .................................................................................................................... 5-9 Management Leadership ........................................................................................................... 5-11

Worker Development ...................................................................................................... 5-19 State of Self-Control and Responsibility ................................................................................... 5-19 Principles for Worker Development........................................................................................... 5-21

Worker Participation and Involvement .......................................................................... 5-35 Types of participation and Involvement .................................................................................... 5-37

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Session 6—Quality and Continuous Improvement The Seven Basic Quality Tools ....................................................................................... 6-7 Six Sigma DMAIC ............................................................................................................ 6-21 Define .......................................................................................................................................... 6-21 Measure....................................................................................................................................... 6-23 Analyze......................................................................................................................................... 6-25 Improve ........................................................................................................................................ 6-25 Control ......................................................................................................................................... 6-27

PDCA Cycle ...................................................................................................................... 6-29 PDCA Activities ............................................................................................................................ 6-31 Plan .............................................................................................................................................. 6-33 Do ................................................................................................................................................. 6-35 Check ........................................................................................................................................... 6-35 Act ................................................................................................................................................ 6-35

A3 Problem Solving ........................................................................................................ 6-37 Problem-Solving A3 Report......................................................................................................... 6-39

Instructor Guide Version 3.3

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Session 7—Design Tradeoffs Design Principles ............................................................................................................ 7-7 Local Design Principles .............................................................................................................. 7-9 Network Design Principles ......................................................................................................... 7-15 Global Design Principles ............................................................................................................ 7-21

Design Techniques .......................................................................................................... 7-25 Supply Network Performance .................................................................................................... 7-25 Improving Supplier Performance and Relationships ............................................................... 7-27 Customer Performance and Relationship Improvements ....................................................... 7-49 Design of Experiments ............................................................................................................... 7-57 Visual Management ................................................................................................................... 7-61 Workplace Design....................................................................................................................... 7-65

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Session 8—Case Studies Case Studies ................................................................................................................... 8-7 Case Study: Productiojn Process Analysis—Overview ............................................................... 8-7 Case Study Part 1: Functional Layout Analysis ......................................................................... 8-9 Case Study Part 2: Cellular Layout Design ................................................................................ 8-25

Appendix Progress Check Answer Sheet ....................................................................................... A-1 Bibliography .................................................................................................................... A-2

Index Index ................................................................................................................................ Index 1

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