[01] INTRODUCTION

In today’s competitive global and business environment, it is essential to have a thorough knowledge and understanding of production planning and scheduling so as to reduce the overall manufacturing costs and thus improve productivity.

Production planning and scheduling are concerned with the volume and timing of outputs, the utilization of operations capacity, forecasting and developing material requirement plans, managing inventory, and managing for world class competition, just-in-time manufacturing and managing for quality.

[02] WHO SHOULD ATTEND

Professionals responsible for optimizing manufacturing processes, improving productivity, and managing costs in a competitive environment includes:

• Production Managers and Supervisors

• Supply Chain and Logistics Managers

• Operations and Plant Managers

• Manufacturing Engineers

• Inventory and Material Planners

• Quality Assurance and Control Personnel

• Business Analysts and Process Improvement Specialists

• Supply Chain Consultants and Lean Practitioners

[03] COURSE OBJECTIVES

• Appreciate the roles of production planning, scheduling and control, and its objectives, functions

• Exercise and enhance your forecasting skills by applying proven methods

• Understand the benefits of aggregate planning and identify the suitable aggregate planning methods for your production plan

• Understand the principles of demand and capacity management, and Master Production Scheduling mechanism

• Identify the process of creating accurate and feasible Master Scheduling for Production (MPS)

• Describe benefits, principles and mechanisms of Material Requirement Planning (MRP)

• Elevate material planning linkage to operational effectiveness

• Learn the reports, evaluation tools and techniques for the analysis of production problems

• Acquire various production planning and control tools

• Improve your production efficiency, save time, cost and inventory

• Extend your professional skills and add your career value

[04] METHODOLOGY

Case studies, small group practical exercises, small group discussion, facilitator presentations, skill practices, application planning and walk-through simulations.

[05] DATE, TIME & FEE

Date:           16-17 Dec 2024 (Mon-Tue)

Time:           9.00am – 5.00pm

Venue:         Sheraton Petaling Jaya

FEE

[ HRDF Claimable ]

   - Early Bird Offer (before 28 Nov 2024) – RM 1680
   - Special Offer (before 12 Dec 2024) – RM 1760
   - Normal Fee – RM 1840

GROUP DISCOUNT

2 Persons - 10% Discount

3 Persons - 15% Discount

>> Fee includes Course Notes, Meals, Certificate of Completion & 8% Service Tax

** OFFER ** 

- 10% Cashback for SST2u Learner Card+ (SLC+) members. T&Cs applied.

[06] COURSE OUTLINE

DAY ONE

Module 1: Operation Management and Production Planning & Control

• Learn the objectives and function of operation management, and the interrelationship between Production Planning & Control

• What is Production Planning about?

• Difference between Production Planning and Production Control

• Activities in Production Planning / Control

• Roles and Responsibilities and interaction with other departments

• Handling Production Planning frustrations

• Elements of Production Planning and Control

• Overall interaction and sequence flow of Production Planning and Control with manufacturing

Module 2: Forecasting

• Why do we need to forecast?

• Recognize the importance of accurate forecast, the types & applications of forecast, and how to apply the proven methods for rational forecast

• Working with suppliers – supplier monitoring and partnership

• Sales order vs forecasting

• The input of forecasts process

• Forecasting methods – quantitative and qualitative

Module 3: Aggregate Planning & Capacity Planning

• Aggregate planning & capacity planning - the differences

• Linkages between capacity planning, aggregate planning, MPS and Short term planning

• Inputs and outputs of Aggregate Planning

• Level planning or chase planning

• Capacity planning adjustment tips – capacity options and demand options and their pros and cons

• Outsource for managing capacity

• Capacity utilization

Module 4: Master Scheduling for Production (MPS)

• Appreciate the accuracy of Master Production Schedule (MPS), and understand the steps and process in doing MPS

• Types of demands (independent and dependent demand)

• Information for MPS logic

• Common terminologies in MPS and MRP

Q&A Session

End of Training

DAY TWO

Module 5: Material Requirements Planning (MRP)

• Comprehend the definitions and benefits of Material Requirements Planning (MRP), and gain knowledge on Bills of Material (BOM) – as critical success factors for MRP implementation

• Bill of Materials (BOM) analysis

• Hierarchy and Levels analysis

• Inputs and outputs of MRP

• MRP primary and secondary outputs

• Activities to calculate BOM and simulation of MRP / MPS

• Order / Planning system for Lot for Lot and Fixed Lot size ordering

Module 6: Production / Operations Scheduling (OS) And Control

• Production Control and JIT concept

• Shop Floor Control – order release, order scheduling and order progress

• Bottleneck management

• Production floor resources management

• Contingency planning in production floor

Module 7: Inventory Management & Stock Control

• Learn to apply ABC analysis for materials management, and recognize the various costs in inventory. Identify the relativity of quantity discounts in inventory management

• Understand the cost of inventory management

• Types of inventories

• Inventories accuracy

• Reorder point

• MRP / MRP II / ERP

• Risk assessment and management in warehouse

 o Identifying hazards and potential risks in warehouse using Warehouse Failure Mode and Effect Analysis (WFMEA) 

 o Project plan for risk elimination and mitigation in warehouse

• EOQ (Economic Order Quantity) for warehouse planning

Module 8: Supplier Management

• Cost of poor quality of suppliers

• Supplier management and development

• Supplier audit

• Managing difficult suppliers

• Supplier selection process

Q&A Session

End of Training

[07] TRAINER PROFILE

YK TANG

Certified Global Supply chain, Black Belt (University of Tennessee), Certified Success Motivation International (USA), Qualified FTEP FMEA Trainer, PSMB Trainer

Tang is an experienced consultant, trainer, and facilitator specializing in Quality and Productivity Improvement, Supply Chain Optimization, Interpersonal and Communication Skills, and Leadership. With over 24 years of hands-on experience in regional operations and productivity, he has worked on numerous global projects across Singapore, Taiwan, China, Thailand, Vietnam, Cambodia, and Malaysia. His expertise spans ISO9001, IATF16949, Lean Sigma, Six Sigma, and Quality Improvement Initiatives, contributing to improved productivity and profitability in various organizations.

Tang holds a Bachelor of Science in Physics and has received comprehensive training in human development, process improvement, ADDIE instructional design, and holistic thinking for adult learning. As a certified Global Supply Chain Black Belt from the University of Tennessee, he focuses on implementing Lean concepts and enhancing supply chain efficiency. His previous role in a major FMCG company in Indochina strengthened his skills in cross-cultural relationship management, conflict resolution, and organizational setup, particularly in business acquisition and process alignment.

Fluent in English, Malay, and Chinese, Tang connects effectively with participants from diverse backgrounds, enhancing the impact of his training sessions. Additionally, he has contributed articles on Quality for Management Systems Asia, sharing his insights with a regional audience. His skills in operations effectiveness, gap analysis, and needs assessment position him as a valuable asset in driving continuous improvement in organizations.

AREA OF SPECIALIZATION:

Consulting, training, coaching and facilitation in the areas of

• Quality and Productivity Improvement

• Supply Chain Optimization

• Interpersonal and Communication Skills

• Teambuilding & Leadership

[08] ENQUIRY & REGISTRATION

Enquiry: yes@sst2u.com

Contact:

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