Production control

Last updated

Production control is the activity of monitoring and controlling any particular production or operation. Production control is often run from a specific control room or operations room. With inventory control and quality control, production control is one of the key functions of operations management. [1]

Contents

Overview

Production control is the activity of monitoring and controlling a large physical facility or physically dispersed service. It is a "set of actions and decision taken during production to regulate output and obtain reasonable assurance that the specification will be met." [2] The American Production and Inventory Control Society, nowadays APICS, defined production control in 1959 as:

Production control is the task of predicting, planning and scheduling work, taking into account manpower, materials availability and other capacity restrictions, and cost so as to achieve proper quality and quantity at the time it is needed and then following up the schedule to see that the plan is carried out, using whatever systems have proven satisfactory for the purpose. [3]

Production planning and control in larger factories is often run from a production planning department run by production controllers and a production control manager. Production monitoring and control of larger operations is often run from a central space, called a control room or operations room or operations control center (OCC).

The emerging area of Project Production Management (PPM), based on viewing project activities as a production system, adopts the same notion of production control to take steps to regulate the behavior of a production system where in this case the production system is a capital project, rather than a physical facility or a physically dispersed service.

Production control is to be contrasted with project controls. As explained, [4] project controls have developed to become centralized functions to track project progress and identify deviations from plan and to forecast future progress, using metrics rooted in accounting principles.

Types

Powerplant control room, 1983 Fotothek df n-34 0000193 Maschinist fur Warmekraftwerke.jpg
Powerplant control room, 1983

One type of production control is the control of manufacturing operations.

Management of real-time operational in specific fields.

Communist countries had a central production control institute, where the agricultural and industrial production for the whole nation was planned and controlled.

In Customer Care environments production control is known as Workforce Management (WFM). Centralized Workforce Management teams are often called Command Center, Mission Control or WFM Shared Production Centers.

Production control is just one of multiple types of control in organizations. Most commons other types are:

See also

Related Research Articles

Supply chain management

In commerce, supply chain management (SCM), the management of the flow of goods and services, involves the movement and storage of raw materials, of work-in-process inventory, and of finished goods as well as end to end order fulfilment from point of origin to point of consumption. Interconnected, interrelated or interlinked networks, channels and node businesses combine in the provision of products and services required by end customers in a supply chain. Supply-chain management has been defined as the "design, planning, execution, control, and monitoring of supply-chain activities with the objective of creating net value, building a competitive infrastructure, leveraging worldwide logistics, synchronizing supply with demand and measuring performance globally". SCM practice draws heavily from the areas of industrial engineering, systems engineering, operations management, logistics, procurement, information technology, and marketing and strives for an integrated approach. Marketing channels play an important role in supply-chain management. Current research in supply-chain management is concerned with topics related to sustainability and risk management, among others. Some suggest that the “people dimension” of SCM, ethical issues, internal integration, transparency/visibility, and human capital/talent management are topics that have, so far, been underrepresented on the research agenda. Supply chain management (SCM) is the broad range of activities required to plan, control and execute a product's flow from materials to production to distribution in the most economical way possible. SCM encompasses the integrated planning and execution of processes required to optimize the flow of materials, information and capital in functions that broadly include demand planning, sourcing, production, inventory management and logistics -- or storage and transportation.

Material requirements planning (MRP) is a production planning, scheduling, and inventory control system used to manage manufacturing processes. Most MRP systems are software-based, but it is possible to conduct MRP by hand as well.

Solarsoft Business Systems is a privately held software company based in Richmond Hill, Ontario, with UK headquarters in Bracknell. The company supplies modern business management systems, enterprise resource planning (ERP) software and IT services to manufacturers, distributors and wholesale businesses across North America, Europe and Asia.

APICS is the association for supply chain management and a not-for-profit international education organization offering certification programs, training tools, and networking opportunities to increase workplace performance. Formed in 1957, the mission of the organization is to advance end-to-end supply chain management. APICS merged with the Supply-Chain Council in 2014, and the American Society of Transportation and Logistics in 2015.

Manufacturing resource planning

Manufacturingresource planning is defined as a method for the effective planning of all resources of a manufacturing company. Ideally, it addresses operational planning in units, financial planning, and has a simulation capability to answer "what-if" questions and extension of closed-loop MRP.

Business Planning and Control System (BPCS) is an Enterprise Resource Planning (ERP) software designed for an OS/400 system. BPCS is a series of software programs that are the largest software supplier for AS/400.

Operations management

Operations management is an area of management concerned with designing and controlling the process of production and redesigning business operations in the production of goods or services. It involves the responsibility of ensuring that business operations are efficient in terms of using as few resources as needed and effective in terms of meeting customer requirements. Operations management is primarily concerned with planning, organizing and supervising in the contexts of production, manufacturing or the provision of services.

Safety stock is a term used by logisticians to describe a level of extra stock that is maintained to mitigate risk of stockouts caused by uncertainties in supply and demand. Adequate safety stock levels permit business operations to proceed according to their plans. Safety stock is held when uncertainty exists in demand, supply, or manufacturing yield, and serves as an insurance against stockouts.

Workforce management (WFM) is an institutional process that maximizes performance levels and competency for an organization. The process includes all the activities needed to maintain a productive workforce, such as field service management, human resource management, performance and training management, data collection, recruiting, budgeting, forecasting, scheduling and analytics.

The following outline is provided as an overview of and topical guide to management:

Materials management is a core supply chain function and includes supply chain planning and supply chain execution capabilities. Specifically, materials management is the capability firms use to plan total material requirements. The material requirements are communicated to procurement and other functions for sourcing. Materials management is also responsible for determining the amount of material to be deployed at each stocking location across the supply chain, establishing material replenishment plans, determining inventory levels to hold for each type of inventory, and communicating information regarding material needs throughout the extended supply chain.

Quick response manufacturing (QRM) is an approach to manufacturing which emphasizes the beneficial effect of reducing internal and external lead times.

Manufacturing execution systems (MES) are computerized systems used in manufacturing to track and document the transformation of raw materials to finished goods. MES provides information that helps manufacturing decision makers understand how current conditions on the plant floor can be optimized to improve production output. MES works in real time to enable the control of multiple elements of the production process.

Industrial engineering Branch of engineering which deals with the optimization of complex processes or systems

Industrial engineering is an engineering profession that is concerned with the optimization of complex processes, systems, or organizations by developing, improving and implementing integrated systems of people, money, knowledge, information and equipment.

Applied engineering education is defined as a program that generally prepares individuals to apply mathematical and scientific principles inherent to engineering to the management and design of systems, execution of new product designs, improvement of manufacturing processes, and the management and direction of the physical or technical functions of an organization. Includes instruction in basic engineering principles, project management, industrial processes, production and operations management, systems integration and control, quality control, and statistics.14.0103 2020 CIP Code

The following outline is provided as an overview of and topical guide to production:

An intelligent maintenance system (IMS) is a system that utilizes collected data from machinery in order to predict and prevent potential failures in them. The occurrence of failures in machinery can be costly and even catastrophic. In order to avoid failures, there needs to be a system which analyzes the behavior of the machine and provides alarms and instructions for preventive maintenance. Analyzing the behavior of the machines has become possible by means of advanced sensors, data collection systems, data storage/transfer capabilities and data analysis tools. These are the same set of tools developed for prognostics. The aggregation of data collection, storage, transformation, analysis and decision making for smart maintenance is called an intelligent maintenance system (IMS).

Industrial and production engineering (IPE) is an interdisciplinary engineering discipline that includes manufacturing technology, engineering sciences, management science, and optimization of complex processes, systems, or organizations. It is concerned with the understanding and application of engineering procedures in manufacturing processes and production methods. Industrial engineering dates back all the way to the industrial revolution, initiated in 1700s by Sir Adam Smith, Henry Ford, Eli Whitney, Frank Gilbreth and Lilian Gilbreth, Henry Gantt, F.W. Taylor, etc. After the 1970s, industrial and production engineering developed worldwide and started to widely use automation and robotics. Industrial and production engineering includes three areas: Mechanical engineering, industrial engineering, and management science.

Operations management for services has the functional responsibility for producing the services of an organization and providing them directly to its customers. It specifically deals with decisions required by operations managers for simultaneous production and consumption of an intangible product. These decisions concern the process, people, information and the system that produces and delivers the service. It differs from operations management in general, since the processes of service organizations differ from those of manufacturing organizations.

Project production management (PPM) is the application of operations management to the delivery of capital projects. The PPM framework is based on a project as a production system view, in which a project transforms inputs into outputs.

References

  1. K.C. Arora. Production and Operations Management. 2004. p. 7
  2. S. N. Ghosh (ed.) Cement and Concrete Science & Technology. 1991. p. 419
  3. APICS (1959) cited in: Kenneth N. McKay, Vincent C. S. Wiers (2004). Practical Production Control: A Survival Guide for Planners and Schedulers, p. 29
  4. "Contrasting Project Production Control with Project Controls," R.J. Arbulu, H-J. Choo, M. Williams, Proc. International Conference on Innovative Production and Construction (IPC 2016), 3–5 October 2016, Darwin, Australia

Further reading