This course covers the basic principles and techniques applicable in the practice of Production and Inventory Management. It is suitable for those working in the field, and wants to obtain or update their professional knowledge, those entering this field or working in a related field such as Purchasing, Accounting, Marketing, Engineering, Data Processing etc.
It aims to provide the students with an-depth understanding of Production & Inventory management as well as assistance in interdepartmental understanding and to instil accountability and responsibility.
It is recommended that a learner should have a minimum of a Grade 12.
One - Resource Planning
Contents
Outcomes, Introduction, Long-Range Planning, Medium-Range Planning, Short-Range Planning, Product and Process Strategies, Alternate Plant Layouts, Summary
Two - Product Development and Process Design
Contents
Outcomes, Introduction, The Product, Production Decisions, Product Management, Product Design, Product Life Cycle, Computers in Product Development, Process Design, Choice of Production Method, Ergonomics and Work Study, Summary
Three - Forecasting and Demand Management
Contents
Outcomes, Introduction, What Is a Forecast?, Data Collection and Accuracy, Forecasting Techniques, Quantitative Forecasting Methods, Mean, Median and Mode, Time-Series Forecasting Models, Forecast Error, Safety Stock and Forecast Uncertainty, Summary.
Four - Master Planning of Resources
Contents
Outcomes, Introduction, The Production Plan, Developing the Production Plan, Master Production Schedule [MPS], Developing the MPS, Rough-Cut Capacity Planning [RCCP], Performance Measurement, Rules for Successful Master Scheduling, Summary
Five - Materials Planning
Contents
Outcomes, Introduction, Objectives of Materials Planning, Dependent vs Independent Demand, Inputs to Materials Planning, The MRP Grid, Materials Planning Outputs, Users and Uses of the Bills Of Material, Performance Measures, Summary
Six - Capacity Planning
Contents
Outcomes, Introduction, The Capacity Planning Process, Key Definitions, Measures of Capacity, Inputs to Capacity Planning, The Capacity Processing Logic, Outputs From Capacity Planning, Input/Output Control, Performance Measures, Summary
Seven - Executing Push Systems
Contents
Outcomes, Introduction, Loading the Factory, Controlling Movement Through the Factory, Managing Push Systems, Authorizing Push Activities, Documentation, Executing Push Activities, Priority Rules, Bottleneck Management, Input/Output Control, Data Collection Techniques, Summary
Eight - Executing Pull Systems
Contents
Outcomes, Introduction, Production Pull Systems, Pull System Characteristics, Kanbans, Line Balancing, Executing Pull Activities, Reporting Pull Activities, Synchronous Manufacturing, Agile Manufacturing, Summary
Nine - Mid Term Exam
Ten - Lean Manufacturing
Contents
Outcomes, Introduction, Lean Manufacturing, 5S Methodology, Theory of Constraints [TOC], TOC and Distribution Management, TOC and Suppliers, TOC and the Team, Advance Planning Systems [APS], Summary
Eleven - Purchasing and Procurement
Contents
Outcomes, Introduction, Objectives of Purchasing, Market Research in Procurement, Selecting Suppliers, The Purchasing Specification, Value Engineering and Value Analysis, The Purchasing Cycle, BEE in Procurement, Stock Pricing and Valuation, Summary
Twelve - Inventory Fundamentals
Contents
Outcomes, Introduction, What is Inventory? Types and Functions of Inventory, Inventory Sub Categories, Inventory Costs, Inventory and Customer Service, Safety Stock Inventory, ABC Classification of Inventory, Control of Inventory, Inventory Performance Measures, Summary
Thirteen - Inventory Methodologies and Techniques
Contents
Outcomes, Introduction, When to Order, “How Often” to Order, Order Review Methodologies, Order Quantity Constraints and Modifiers, Lot Sizing Techniques, Quantity Discounts, Summary
Fourteen - Total Quality Management
Contents
Outcomes, Introduction, Defining Quality, Design and Conformance, The Quality Gurus, Four Absolutes of Quality, Total Quality Management, Responsibility for Quality, Quality Costs, Inspection, Quality Training, Quality and Customer Satisfaction, Summary
Fifteen - Statistical Quality Control
Contents
Outcomes, Introduction, Quality Tools, The “Normal” Distribution, Control Charts, Interpretation of Control Charts, Process Capability, Acceptance Sampling, Sampling Plans, Summary
Sixteen - Warehousing and Materials Handling
Contents
Outcomes, Introduction, Space Requirements, Warehouse Productivity, Storage Methods, Storage Equipment, Order Picking Systems, Materials Handling, Classification of Equipment, Docking Aids, Summary
Seventeen - Distribution Management
Contents
Outcomes, Introduction, Distribution Networks, Activities of Physical Distribution, Distribution Centre Management, Distribution Requirements Planning, DRP], Ordering Models, Managing Day-to-Day Variations, Summary
Eighteen - Facilities Location and Transportation
Contents
Outcomes, Introduction, Facility Location, Site Selection, Transportation, Designing the Transportation System, Freight Management, Modes of Transport, Containerization, Packaging and Labeling, Summary
Nineteen - Final Exam
This course introduces the student to the Basics of Production & Inventory management. Targets persons from all functions in an organisation at an introductory level. It aims to provide a basic insight into P&IM systems and provide assistance in the development of inter-departmental understanding and communication.
There are no formal qualifications for entry onto this course, although a candidate must have basic numeracy.
The importance of the storekeeping function is often overlooked. This seems incomprehensible when you consider the value of stock this function is responsible for. This course is targeted at all stores personnel, including the store man and all first-line supervisors. Other major users of the stores function also gain specific benefit from attending this course.
The aim is to introduce candidates to the concepts of stock control and to develop stores control personnel who are able to accept responsibility through the understanding of the requirements of their function.
Basic literacy in English, and a basic understanding of numeracy.
This 30 hour course gives provision of an understanding of the objectives, principles and techniques of warehouse management at a level of detail suitable for the practitioner. Course assignments and attendance at the classes provide a good grounding across the full spectrum of warehouse management. It targets Marketing, Costing & Finance, Manufacturing, Engineering & Development, Materials management, Production control and Information technology persons.
Basic literacy in English and numeracy, and a working understanding of mathematical equations is recommended.
