Format: Live instructor-led online training via Zoom / Microsoft Teams

Production Planning and Control Training Course

Course Overview

Production Planning and Control (PPC) is a critical function in modern manufacturing and operations management that ensures the efficient utilization of resources, timely production scheduling, inventory optimization, quality assurance, and on-time delivery of products. This comprehensive training course provides participants with practical knowledge and advanced skills in production planning, production scheduling, capacity planning, inventory management, materials requirement planning (MRP), demand forecasting, workflow optimization, and production performance monitoring. The course is designed to help organizations improve productivity, reduce operational costs, enhance customer satisfaction, and achieve operational excellence through effective production management systems.

In today's highly competitive business environment, organizations must effectively coordinate materials, labor, machinery, information, and logistics to meet customer demands while maintaining profitability. This course explores the principles and practices of production planning and control, focusing on production forecasting, master production scheduling, shop floor control, supply chain integration, quality management, lean production systems, and continuous improvement methodologies. Participants will gain practical tools for balancing production capacity with market demand while minimizing waste and maximizing efficiency.

The training emphasizes the use of modern production planning techniques, enterprise resource planning (ERP) systems, digital manufacturing technologies, inventory optimization strategies, and performance measurement frameworks. Through real-world case studies and practical exercises, participants will learn how to identify production bottlenecks, improve workflow efficiency, reduce lead times, enhance resource utilization, and improve overall manufacturing performance. The course also addresses risk management, production flexibility, and resilience in dynamic operating environments.

By the end of the training, participants will have the competencies required to develop effective production plans, implement robust production control systems, improve coordination across departments, optimize inventory levels, and drive continuous operational improvements. The skills acquired will enable organizations to achieve higher productivity, lower costs, improved product quality, enhanced customer service, and sustainable competitive advantage.

Course Objectives

Upon successful completion of the course, participants will be able to:

1.     Understand the principles and functions of production planning and control.

2.     Develop effective production schedules and operational plans.

3.     Apply forecasting techniques for production decision-making.

4.     Optimize inventory management and material requirements planning.

5.     Improve production capacity planning and resource allocation.

6.     Implement shop floor control and production monitoring systems.

7.     Identify and eliminate production bottlenecks.

8.     Utilize ERP and digital tools for production management.

9.     Measure and improve production performance using key indicators.

10.  Develop continuous improvement initiatives for operational excellence.

Organizational Benefits

Organizations whose staff attend this training will benefit through:

1.     Improved production efficiency and productivity.

2.     Reduced production delays and lead times.

3.     Better inventory management and cost reduction.

4.     Enhanced utilization of labor, equipment, and materials.

5.     Improved production quality and consistency.

6.     Increased customer satisfaction through timely delivery.

7.     Better coordination between production and supply chain functions.

8.     Improved production forecasting and demand management.

9.     Reduced operational waste and production costs.

10.  Enhanced competitiveness and profitability.

Target Participants

This course is suitable for:

·       Production Managers

·       Operations Managers

·       Manufacturing Managers

·       Plant Managers

·       Production Supervisors

·       Industrial Engineers

·       Supply Chain Managers

·       Logistics Managers

·       Procurement Officers

·       Inventory Controllers

·       Planning Officers

·       Quality Assurance Managers

·       Maintenance Managers

·       ERP System Users

·       Business Improvement Specialists

·       Project Managers

Course Outline

Module 1: Introduction to Production Planning and Control

1.     Fundamentals of production planning and control

2.     Objectives and functions of PPC

3.     Production systems and manufacturing environments

4.     Production planning framework

5.     Role of PPC in operational excellence

6.     Case Study: Effective production planning in manufacturing

Module 2: Demand Forecasting and Production Planning

1.     Forecasting principles and methods

2.     Qualitative forecasting techniques

3.     Quantitative forecasting models

4.     Sales and operations planning

5.     Forecast accuracy measurement

6.     Case Study: Improving production planning through forecasting

Module 3: Capacity Planning and Resource Management

1.     Capacity planning concepts

2.     Resource allocation strategies

3.     Workforce planning and utilization

4.     Equipment capacity management

5.     Capacity balancing techniques

6.     Case Study: Optimizing production capacity utilization

Module 4: Master Production Scheduling (MPS)

1.     Production scheduling fundamentals

2.     Developing master production schedules

3.     Production sequencing techniques

4.     Schedule optimization methods

5.     Managing schedule changes

6.     Case Study: Enhancing production scheduling efficiency

Module 5: Materials Requirement Planning (MRP)

1.     Introduction to MRP systems

2.     Bill of materials management

3.     Inventory data management

4.     Material planning processes

5.     MRP implementation strategies

6.     Case Study: Improving material availability through MRP

Module 6: Inventory Planning and Control

1.     Inventory management principles

2.     Inventory classification methods

3.     Economic order quantity (EOQ)

4.     Safety stock and reorder points

5.     Inventory optimization techniques

6.     Case Study: Reducing inventory costs while maintaining service levels

Module 7: Shop Floor Planning and Control

1.     Shop floor management concepts

2.     Work order management

3.     Production monitoring techniques

4.     Workflow management systems

5.     Production reporting and control

6.     Case Study: Improving shop floor productivity

Module 8: Lean Production and Continuous Improvement

1.     Lean manufacturing principles

2.     Waste identification and elimination

3.     Value stream mapping

4.     Continuous improvement techniques

5.     Kaizen implementation strategies

6.     Case Study: Lean production transformation

Module 9: Quality Planning and Production Control

1.     Quality management principles

2.     Statistical process control

3.     Production quality monitoring

4.     Defect prevention strategies

5.     Quality performance measurement

6.     Case Study: Enhancing quality through process control

Module 10: ERP Systems and Digital Production Management

1.     ERP fundamentals for production planning

2.     Production information systems

3.     Digital manufacturing technologies

4.     Real-time production monitoring

5.     Data-driven decision making

6.     Case Study: ERP implementation for production optimization

Module 11: Production Performance Measurement

1.     Key performance indicators (KPIs)

2.     Productivity measurement systems

3.     Efficiency and utilization analysis

4.     Production cost monitoring

5.     Performance reporting dashboards

6.     Case Study: Improving operational performance through KPIs

Module 12: Strategic Production Planning and Operational Excellence

1.     Strategic production management

2.     Supply chain integration

3.     Risk management in production planning

4.     Sustainable manufacturing practices

5.     Building a culture of operational excellence

6.     Case Study: Achieving world-class manufacturing performance

General Information

1.     Customized Training: All our courses can be tailored to meet the specific needs of participants.

2.     Language Proficiency: Participants should have a good command of the English language.

3.     Comprehensive Learning: Our training includes well-structured presentations, practical exercises, web-based tutorials, and collaborative group work. Our facilitators are seasoned experts with over a decade of experience.

4.     Certification: Upon successful completion of training, participants will receive a certificate from Foscore Development Center (FDC-K).

5.     Training Locations: Training sessions are conducted at Foscore Development Center (FDC-K) centers. We also offer options for in-house and online training, customized to the client's schedule.

6.     Flexible Duration: Course durations are adaptable, and content can be adjusted to fit the required number of days.

7.     Onsite Training Inclusions: The course fee for onsite training covers facilitation, training materials, two coffee breaks, a buffet lunch, and a Certificate of Successful Completion. Participants are responsible for their travel expenses, airport transfers, visa applications, dinners, health/accident insurance, and personal expenses.

8.     Additional Services: Accommodation, pickup services, freight booking, and visa processing arrangements are available upon request at discounted rates.

9.     Equipment: Tablets and laptops can be provided to participants at an additional cost.

10.  Post-Training Support: We offer one year of free consultation and coaching after the course.

11.  Group Discounts: Register as a group of more than two and enjoy a discount ranging from 10% to 50%.

12.  Payment Terms: Payment should be made before the commencement of the training or as mutually agreed upon, to the Foscore Development Center account. This ensures better preparation for your training.

13.  Contact Us: For any inquiries, please reach out to us at training@fdc-k.org or call us at +254712260031.

14.  Website: Visit our website at www.fdc-k.org for more information.