Discuss Production Activity Control

Hello readers, i hope all of you doing well in whatever you are involved. So today, i am going to discuss about production activity control.

INTRODUCTION

Production Activity Control (PAC) is responsible to execute the master production schedule and the material requirements plan. There are some materials requirements plan authorizes PAC:-

• To release work orders to the shop for manufacturing.
• To take control of work orders and make sure they completed on time.
• To manage day-to-day activity and provide the necessary support or backup plan.

Additional info:-  Work orders meant written order from the customer providing specific or blanket authorization to the contractor to proceed with the performance. 

FUNCTION OF PAC

There are three major functions in activity controls. The  activities of the PAC system can divided into planning, implementation and controls function. 

1. Planning

- ensure that the required materials, tooling, personnel & information are available to manufacture

-to run production those elements must be complete.

-schedule start and completion dates for each shop order.

2. Implementation

-after plan it must put them in action.

-gather information needed by the shop floor 

-release order to the shop floor

3. Control

-rank the shop orders in desired priority sequences by work center.

-track the actual performance of work orders and compare with planned schedule.

-monitor & control work-in-process, lead time, and work center queues.

-report work center efficiency, operation times, order quantities and scrap.

MANUFACTURING SYSTEMS

Manufacturing process can be organized into three categories:

1. Flow manufacturing

2. Intermittent manufacturing

3. Project manufacturing

DATA REQUIREMENTS

Information needed:

-what & how much to produce

-when parts are needed so the completion date can be met

-what operation are required and how long the operation will take

-what are available capacities of the various work center are

PLANNING FILES- there are four planning file needed which are item master file,                         product structure file, routing file, and work center.

Item Master File:-

• part number, unique number assigned to a component
• part description
• manufacturing lead time
• quantity on hand
• quantity available
• allocated quantity to specified work orders
• on-orders quantities, the balance due on all outstanding orders
• lot-size quantity, the quantity normally ordered at one time

Product Structure File:- contains a list of the single-level components and quantities needed to assemble a parent.

Routing File:-

• the operations required to make the product and the sequence in which those operation are performed
• a brief description of each operation
• equipment, tools, and accessories needed for each operation
• setup times, the standard time required for setting up the equipment for each operation
• run times, the standard time required to process one unit through each operation
• lead time for each operation

Work Center File:-

• work center number
• capacity
• number of shifts worked per week
• number of machine hours per shift
• number of labor hours per shift
• efficiency
• utilization
• queue time, the average time that a job waits at the work center before work is begun
• alternate work centers, work centers that may be used as alternatives 

Control File:-

• shop order master file
• shop order number
• order quantity
• quantity completed
• quantity scrapped
• quantity of material issued to the order
• due dale, the dale the order is expected to be ahead
• priority, a value to rank the order in relation to others
• balance due, the quantity not yet completed
• cost information

Shop Order Detail File:-

• operation number
• setup hours, planned and actual
• run hours, planned and actual
• quantity reported complete at that operation
• quantity reported scrapped at that operation
• due date or lead time remaining