Production Planning and Control Training

The key  for real Lean Production success

One of the keys to Toyota’s success is the role that Production Planning and Control plays in the organization.

Production Planning and Control is the voice of the Customer to manufacturing and conversely it is the section that manages information flow from the Customer, Suppliers, Manufacturing and Engineering.

As Atsushi Niimi (former President of TMMNA) once said, “PPC is where the real power of Toyota is”.

Hands On – Gemba Workshop at Host Company

Learn to Map the entire Supply Chain
Learn to Map the entire Supply Chain

Identify & Analyze the main opportunities from the supply chain with a real value stream mapping in the host company.

Group Discussion
Group Discussion

Share experiences with supply chain professional from different industries and background.

Real Implementation
Real Implementation

The training is based on a real project environment to define a production plan and its requirements.

TRAINING DETAILS

Training Lenght:

24 Hours (3 days)

Who should attend?

General Managers, Managers and Supervisors in Supply Chain, Production Planning or Lean Implementation that would like to understand how to maintain a consistent flow of information while supplying the plants with Just in Time product and materials.

Recommended industries:

Manufacturing Companies: Automotive, Electrical/Electronic, Pharmaceutical, Food & Beverages, Printing, Plastics, among others.

BENEFITS

Participants will understand the Toyota Way in:

  • How to create a Production Forecast
  • How to smooth a weekly production schedule.
  • How to facilitate a Production Forecast Meeting
  • How to adjust daily production based on Pull System.

TRAINING AGENDA: BODY OF KNOWLEDGE

Day One: Introduction & Planning
  • 4 hrs.
    • Role of PPC in a Lean Company
    • Current Planning vs Production Planning and Control(PPC)
    • Creating a Production Planning Group
    • Creating a Production Plan (Theory)
      • Defining TAKT time
      • Creating a Production Forecast
      • Creating the Production Plan
    • 4 hrs
      • Go, See and Understand (Gemba) at planning.
      • Gemba Walk Production Line
        • Map current State production plan
        • Value finished Goods
        • Create Production Board(Maintenance Support)
        • Create Finished Good Kanban (Staff Support)
Day Two: Hands on!
  • 50% of Team. 6 hours
    • Select Target Product Line(cell)
    • Create Production 2 month production forecast 1-month firm plan.
    • Create Weekly Plan
    • Set Min~ Max inventory Targets
  • 50% of Team. 6 hours.
    • Inventory Finished Goods
    • Create Daily production pattern
    • Set up Kanban Board Kanbans
    • Production Team/Conveyance Training
  • Entire Team, Production Manager, Conveyance Manager. 2 hour
    • Status check
    • Roadblocks and Countermeasure.
    • Develop checklists
Day Three: Implementation & Reporting
  • 6 hours.
    • Assign each member to small group of 2~3.
    • Process confirmation.
    • List Problems
  • Report Out. 2 hours.
    • Reports Results
    • Report lessons learned
    • Create host company homework

In this course we will:

  • Show the Roles and Responsibility of PPC in a lean organization.
  • Create a smoothed weekly Production Plan that will absorb order fluctuation.
  • Create a Kanban Replenishment system to drive Just in Time Production while maintaining minimum and maximum inventory levels of finished goods
  • Measure the results of our trial.

This workshop will give the participant a chance to create a Production Forecast and Firm Plan, create a weekly plan, and create a Kanban control board to regulate production (replenishment) and confirm production readiness (Man, Method, Machine and Material).

Production Planning & Control Introduction

PREVIOUS WORKSHOPS

Gemba Workshop at Daimler

Gemba Workshop at SKF

Reasons to work with us

Our Team

We have an exceptional team of collaborators, which includes bestselling authors, former executives from Toyota and other Lean companies and professionals with deep knowledge in the Lean philosophy.

Our Customers

We have had the chance to support over 300 companies, which are compounded by the major manufacturers and services providers across the globe.

Our Methods

We have innovative training systems and programs for accurate professionals’ development, like Lean simulators, Blended Learning, Toyota Kata and Gemba Workshops.

Do you want to go further? we can answer any question

CONTACT US

Contact Us

Let us know your questions, our team will contact you briefly.