production planning.ppt
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Transcript of production planning.ppt
Sales Forecast depend upon sales demand
Sales Operation Planning
Material Requirement Planning(MRP)
Monthly Process Order
BOM
Resource
Receipe
Materials to Be used to produceFG(Finish goods) or SFG (Semi finish goods)
Various Activities and Cost center
Process formation andIndividual rates of
activities
Purchase Requisition(PR)
Purchase Order(PO)
Goods Receipt(GR)
Quality Recording
Unrestricted Stock
updation
Quality configured
Quality StockUpdated
Yes
No
Release of Process Order
Updation of Costing sheet forPlanned activity
and Material Reservation
Will Generate accordingTo Order
Daily Confirmation ofProcess Order
Updation of Costing sheet
for Actual activity and
Material Consumption Will book as
per confirmation
Finish Goods/Semi finish Goods
Unrestricted Stock updation
Quality Recording
Quality configured
Quality StockUpdated Yes
No
Finish goods is madeAvailable for
Despatch And SFG isAvailable for next process
Process of PP/QM module
JK LAKSHMI DURG RESOURCES
Sl No Resource Total No Capacity Unit Full Unit
1 Crusher 1 850 TPH Ton per hour
2 Coal Mill 1 50 TPH Ton per hour
3 Raw Mill 1 400 TPH Ton per hour
4 Kiln 1 4500 TPD Ton per Day
5 Slag Mill 1 100 TPH Ton per hour
6 Paddel Mixture 1 225 TPH Ton per hour
7 Cement Mill 2 80 TPH (Each) Ton per hour
BOM Has Created for Following Materials in Quality Server
SL No Description Code Material Type
1 Crusher Feed A1301010006 Crusher Feed
2 Crushed Lime Stone A1301010002 Raw Material
3 Raw Meal A1301010003 Semi Finish Goods
4 Clinker A1301010001 Semi Finish Goods
5 Fine Coal A1301010004 Fuel
6 Grounded Slag A1000050014 Raw Material
7 Loose Cement OPC-53 Grade A1401010003 FG
8 Loose Cement OPC-43 Grade A1401010002 FG
9 Loose Cement PPC A1401010004 FG
10 Loose Cement PSC A1401010024 FG
SLNO
RESOURCE NAME COST CENTER
NAME ACTIVITIES
1 DUMC01 CEMENT MILL -1 DURG
1120020602 CEMENT MILL NO1 DURG
MACHINE,LABOR,POWER
2 DUMC02 CEMENT MILL -2 DURG
1120020603 CEMENT MILL NO2 DURG
MACHINE,LABOR,POWER
3 DUCOLMIL COAL MILL 1120020401 COAL MILL DURG
MACHINE,LABOR,POWER
4 DUCRUSH1 CRUSHER DURG 1
1120020201 CRUSHER DURG MACHINE,LABOR,POWER
5 DUKILN1 KILN DURG 1120020501 KILN DURG MACHINE,LABOR,POWER
6 DUMINES LAKSHMI CEMENT LS
MINES
1120020107 MINES PRODUCTION
OIL&LUB,LABOR,POWER,EXPLOSIVE,ROYALTY&HEALTH CESS,HANDLING COST
7 DURM01 RAW MILL 1120030101 RAW MILL NO. 1 -DURG
MACHINE,LABOR,POWER
8 DUPKU01 PACKING PLANT UNIT 1
1120020702 PKG PLANT UNIT1-DURG
MACHINE,LABOR,POWER
9 DUSLG SLAG-DURG 1120020901 SLAG GRINDING MACHINE,LABOR,POWER
Resources Has Created for Following in Quality Server
Recipe Has Created for Following in Quality Server
SLNO RECIPE NO NAME
1 50000485 LOOSE CEMENT OPC-53 GRADE
2 50000486 CLINKER
3 50000487 RAW MEAL
4 50000488 FINE COAL
5 50000489 CRUSHER FEED
6 50000490 CRUSHED LIME STONE
7 50000491 GROUNDED SLAG
8 50000492 LOOSE CEMENT PSC (SLAG MILL)
9 50000493 LOOSE CEMENT PSC (PADDEL MIXTURE)
10 50000494 GROUNDED SLAG (SEMIFINSH)
11 50000495 LOOSE CEMENT OPC-43 GRADE
12 50000496 LOOSE CEMENT PPC GRADE
Storage Locations for material storage Has Created for Following in Quality Server
SLNO STORAGE LOCATION NAME
1 5015 CLINKER SILO
2 5016 OPC43 CEMENT SIL
3 5017 OPC53 CEMENT SIL
4 5018 PPC CEMENT SILO
5 5019 PSC CEMENT SILO
6 5021 SLAG SILO
7 5031 LIME STONE YARD
8 5032 SLAG YARD
9 5049 CRUSHER FEED YAR
10 5050 FACE REJECT
11 5051 SCREEN REJECT
12 5052 C F SILO
13 5053 IRON ORE YARD
SLNO STORAGE LOCATION NAME
14 5054 BAUXITE ORE YARD
15 5055 SAND STORAGE YARD
16 5060 ALTERNATIVE FUEL
17 5061 COAL YARD IND
18 5062 COAL YARD IMP
19 5063 PET COKE YARD
20 5064 HIGH ASH COAL
21 5065 GYPSUM YARD
22 5066 FLY ASH BUNKER
23 5067 FLY ASH YARD
24 UNT1 PACKED CEMENT
Some key practices followed by JKPURAM Plant
1. Process order created monthly at each production stage for all SFG and FG.
2. Seperate process order has to created for each SFG/FG combination of Line/Resource Used For Example : We have two no of cement mills and our FG are 3 than we have To create 3X2=6 process orders for month.
3. During process order creation, masters like Recipe, BOM etc. are copied automatically to the order as per selection of master recipe and production version provided they are maintained for that SFG/FG correctly before creation of the Process order.
4. Process order to be released when the production as to be executed.
5. On order confirmation BOM components will reserved automatically against The process order.
6. After all transaction are complete the order will be closed at end of month and Above cycle will start for new month/plan
Sl No Resource Total No No of Process Orders for month
1 Crusher Feed 1 1
2 Crusher 1 1
3 Coal Mill 1 1
4 Raw Mill 1 1
5 Kiln 1 1
6 Slag Mill 1 1
7 Paddel Mixture 1 1
8 Cement Mill 2 * 2X3=6
Monthly process order will created as resources are
* Assuming 3 nos of Finish Goods