Study-unit PRODUCTION PLANNING
| Course name | Engineering management |
|---|---|
| Study-unit Code | A002966 |
| Curriculum | Comune a tutti i curricula |
| Lecturer | Lorenzo Tiacci |
| Lecturers |
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| Hours |
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| CFU | 8 |
| Course Regulation | Coorte 2022 |
| Supplied | 2024/25 |
| Learning activities | Caratterizzante |
| Area | Ingegneria gestionale |
| Sector | ING-IND/17 |
| Type of study-unit | Obbligatorio (Required) |
| Type of learning activities | Attività formativa monodisciplinare |
| Language of instruction | English |
| Contents | Introduction to production systems Basic concepts for the management of production systems Managing items with stationary and independent demand Managing items with dependent demand Just-in-time, Lean Production and Six Sigma. |
| Reference texts | ADOPTED: Tiacci, L., "Gestione delle Scorte - Modelli matematici e loro applicazione - 2A EDIZIONE", Lulu, 2021. (acquistabile al link: http://www.lulu.com/spotlight/LorenzoTiacci) Sianesi, A., "La Gestione del Sistema di Produzione", ETAS, 2011. SUGGESTED: Nahmias, S., "Production and Operations Analysis" - Sixth Ed. - McGrawHill, 2013 Silver, E.A., Pyke, D.F., Thoms, D.J., "Inventory and Production Management in Supply Chains" - Fourth Ed. - CRC Press 2017. Silver, E.A., Pyke, D.F., Peterson, R., "Inventory Management and Production Planning and Scheduling" - Third Ed. - WILEY 1998. Schiraldi, M., "La gestione delle scorte", Esselibri, 2007. Chopra, S. , Meindl, P., "Supply Chain Management", Pearson, 2007. |
| Educational objectives | The course objective is to provide basic knowledge for the management of a production system as a whole, in order to optimize its performances in terms of costs reduction and service level fulfillment. The main knowledge gained will be: definitions and classifications of production processes and production systems knowledge related to productivity and efficiency measures theoretical knowledge on materials management, such as inventory control policies for items with independent demand theoretical knowledge related to material with dependent demand, such as heuristic for lot sizing, forecasting, and basic concepts of Material Requirement Planning Basic knowledge of Just in Time and Lean Production The main skills are: application of forecasting techniques on historical data for the calculation of future requirements Ability to develop the Sales and Operations Plan (S & OP) Ability to develop Master Production Schedule (MPS) Ability to optimize order quantities and reorder points Ability to optimize the time interval between orders and the order-up-to levels |
| Prerequisites | In order to understand and to apply most of the techniques described in the course it is essential the knowledge of the following topics: - Integral, indefinite integrals, multi-variable functions, maximum and minimum bounded - Probability density functions, basic concepts of statistics. It is also important to have succesfully taken an exam about Facilities Planning. |
| Teaching methods | The course is organized as follows: - Theoretical lessons on all topics of the program - Classroom exercises consisiting in solving practical problems The exercises are held during class time, and immediately follow the theoretical lesson to which they refer |
| Other information | Attendance is not compulsory but strongly adviced. |
| Learning verification modality | The exam consists of a written exam and an oral exam. The written exam consists in an exercise in which the student has to solve a problem related to subject as demand forecasting, inventory control, MRP. The exercise aim is to determine the ability to correctly apply the theoretical knowledge, the understanding of the issues proposed, and the concentration ability needed to perform correctly the calculation needed to solve the problem. The test duration is approximately 1h 30m The oral exam consists of 3 questions designed to ascertain the level of knowledge and understanding of the issues on theoretical and methodological aspects of the program. The duration of the test is about 30 min. |
| Extended program | Introduction to Production Systems Definitions of production system and production process The classification of the production processes and production systems Classification of "products” Classification based on the management methods adopted (push and pull approaches) Classification based on technological processes Classification of assembly based on work organization Classification based on the lay out The classifications of synthesis Performance measurement Classification models for performances and operating conditions The measurement of the operating conditions The operating statuses of a resource The availability of a productive resource production potentiality and production rate The measure of use, productivity and yield The measure of use, productivity and yield The measure of the OEE Production costs Models for demand forecasting Correlation for market demand forecasting Extrapolation The components of the demand Possible demand models Intervals and periods The static method Self-adaptive methods Measures of errors Tuning of self-adaptive forecasting methods Monitoring and Controlling Forecasts General concepts related to stocks Classification of stock types Classification of stocks based on the state of transformation Stocks classification based on the performed functions The relevant costs for decisions Stock keeping costs Replenishment costs Stock out costs Models for items with constant and deterministic demand Quantity of reorder with approximately constant question The economic order quantity (EOQ) Sensitivity analysis Quantity discounts The economic production quantity (EPQ) Considering deterministic lead times Models for items with time-varying and deterministic demand The Wagner-Whitin method The Silver-Meal heuristic The “least unit cost” (LUC) heuristic The "part period balancing" (PPB) heuristic The "lot for lot" (L4L) method Fixed quantity and fixed period methods Models for items with probabilistic demand Definitions and notation CONTINUOUS REVIEW POLICY (s, Q) (order point, order quantity) Strengths and weaknesses Common derivation Setting the (s, Q) policy for individual items Allocation of a certain amount of safety stock (in value) among several items Selecting the design criteria The exchange curves PERIODIC REVIEW POLICY (R, S) (review period, order up to level) Strengths and weaknesses Common derivation Equivalence formulas for (R,S) policy and policy (s,Q) Setting the (R, S) policy for individual items The choice of reorder period in the case of multiple items Variability in the replenishment lead time The connection between demand forecasting and inventory control How to estimate the average demand How to estimate the standard deviation of errors during the lead time The "requirement management" techniques The general framework of requirement management systems From stock management systems to requirement-based management systems General concepts related to requirement management systems Demand planning and forecasting Aggregate sales planning and capacity management The sales and operations planning process The relevant costs in medium-term planning The Sales and Operations Plan (S&OP) The Master Production Schedule (MPS) The logical flow from the S&OP to the MPS The level and chase approaches for the formulation of the MPS The Rough Cut Capacity Plan The models for the formulation of the MPS Requirements planning (MRP) The basic concepts of MRP systems Short term scheduling notes Introduction and classification of scheduling problems Examples of solutions for job allocation to machines Examples of techniques for the formulation of the operational pian Just In Time, Lean Production and Six Sigma to improve the production system Introduction to Quality Management and Operations improvement methodologies The Toyota Production System The 14 Principles of Toyota Way From the principles to the implementation of the TPS The Kaizen approach and continuous improvement Techniques and tools for implementing TPS Data Collection Sheet Histograms The "5 WHYs" Cause-and-effect diagrams Control Charts The 5Ss Poka Yoke Leveling of the Master Production Schedule (Heijunka) Pull management of production and suppliers: the Kanban system Six Sigma The key principles of Six Sigma Statistical foundations of Six Sigma methodology The organizational structure and roles of Six Sigma |
| Obiettivi Agenda 2030 per lo sviluppo sostenibile | Questo insegnamento concorre alla realizzazione degli obiettivi ONU dell'Agenda 2030 per lo Sviluppo Sostenibile |