2. Aggregate Production Plan
Aggregate production plans or production planning
is to determine the level or rate of production plants
in the aggregate stated that plans are made for all
products that use the same source, without
elaborated in each of the different products
3. Aggregate Production Plan Objective
Set production strategy
Producing appropriate demand
Determine resource requirements
The first step for all production activities
4. Aggregate Planning Strategies
Chase Strategies
Match demand during the planning horizon by either
Vary workforce or vary output rate
Level Strategies
Maintain a constant workforce level or constant output rate during the
planning horizon
Constant workforce or constant output rate
Mixed Strategies
Combined several strategies
5. Master Production Schedule (MPS)
Master production schedule (MPS) is a statement of
the final product to be produced in the form of
number and time
6. Four Importance Function of the MPS
Schedule the production and purchase of materials
for the product (item).
Make data input material requirements planning
system. MPS are translated using the BOM to
determine the amount of material components and
assembly needs so that MPS can be met.
As the basis for determining resource
requirements, such as labor, machine hours, or
energy through a rough calculation of capacity
planning.
As the basis for determining product delivery
promises to customers.
7. The effects if not properly structured MPS:
1. Production does not match request
2. Not optimal capacity utilization
3. Delay in delivery time
4. Load uneven production
8. Disaggregation
Disaggregation process is a process of equalization of
aggregate units into units of end item based on the
conversion factor, the results of this disaggregation
of a master production schedule / MPS
This disaggregation process objective is to develop
the master production schedule (MPS) after the
aggregate production schedules know.
Disaggregation technique:
Precentage Techniques
Bitran and Hax Methods
9. RCCP (Rough Cut Capacity Planning)
rough-cut capacity planning (RCCP) - used to
check feasibility of MPS. Converts MPS from
production needed to capacity required, then
compares it to capacity available.
10. Four steps RCCP
1. Obtain information about the production plans of
the JIP
2. Obtain structural information and the product lead
time (Lead Time)
3. Determining the Bill of Resources
4. Calculate the specific resource requirements and
create reports RCCP
11. RCCP Techniques
1. Bill Of Labour Approach (BOLA)
2. Capacity Planning Using Overall Factor (CPOF)
12. Bill of Labour Approach (BOLA)
BOLA - using standard time detailed data for each
unit of product.
Capacity Requirement = Total production x operation time
14. CPOF (Capacity Planning Using Overall
Factor)
There are three inputs to calculating RCCP using
CPOF methods:
1. MPS
2. Total time required to produce a product
3. The proportion of time the use of source
15. CPOF (Capacity Planning Using Overall
Factor)
MPS Bill of Resources
WC Time
1 0,1
2 0,8
3 0,22
• The proportion of time the use
of source : 0,1/1,12 = 0,089
17. Decisions taken based on RCCP
1. Calculating Capacity – involves the
relationship below:
Capacity = Available time X Utilization X Efficiency
where:
Available time - total production time available for production
purposes.
Utilization - is the proportion that measures how intensely a resource
is being used.
Efficiency - is the proportion that measures how closely
predetermined standards such as productivity index are achieved.
18. Decisions taken based on RCCP (Cont.)
2. Comparing the available capacity with the required
capacity.
When capacity is not enough, some of the basic
choices available to increase capacity:
a. Overtime
b. Subcontracting
c. Alternate Routing
d. Hiring and Layoff
e. MPS Revision
