Production Planning and Control (PPC) Course

Lesson 1 • PPC Objectives and Functions

Defines the goals of PPC and the interrelated functions that achieve them. Connects planning, scheduling, and control as an integrated system.

Lesson 2 • Demand and Supply Fundamentals

Introduces demand patterns and supply constraints that drive planning decisions. Builds understanding of the demand-supply balance central to PPC.

Lesson 3 • Introduction to Production Systems

Covers types of production systems and their operational characteristics. Provides the baseline vocabulary needed for all subsequent PPC topics.

Lesson 1 • Qualitative Forecasting Methods

Covers judgement-based techniques used when historical data is limited or unreliable. Appropriate for new products and market-entry scenarios.

Lesson 2 • Forecast Accuracy and Error Analysis

Introduces metrics to measure and improve forecast performance. Enables continuous refinement of forecasting models used in production planning.

Lesson 3 • Collaborative Forecasting Practices

Explores cross-functional and supply-chain-wide forecasting collaboration. Prepares students to implement consensus-based demand planning processes.

Lesson 4 • Forecasting Concepts and Importance

Explains why forecasting is the starting point of production planning and the cost of forecast error. Links forecast quality directly to inventory and capacity decisions.

Lesson 1 • Capacity Options in Aggregate Planning

Examines workforce and equipment levers used to adjust capacity. Connects capacity decisions to cost structures and operational flexibility.

Lesson 2 • Aggregate Plan Optimization Methods

Introduces graphical, tabular, and linear programming methods for optimising aggregate plans. Students build and solve basic aggregate planning models.

Lesson 3 • Aggregate Planning Strategies

Covers chase, level, and mixed strategies for aligning production with demand. Students evaluate trade-offs in cost, workforce stability, and inventory.

Lesson 4 • Aggregate Planning Concepts

Defines aggregate planning scope, time horizon, and its position between strategic and operational planning. Establishes the link between forecasts and resource allocation.

Lesson 1 • Rough-Cut Capacity Planning

Introduces RCCP as a quick feasibility check on the MPS before detailed planning. Connects MPS quantities to key work centre and resource requirements.

Lesson 2 • Developing the Master Schedule

Covers the step-by-step process of building an MPS from forecasts and customer orders. Students practise calculating projected available balance and available-to-promise.

Lesson 3 • MPS Concepts and Structure

Defines the master production schedule, its time buckets, and its role as the primary driver of MRP. Establishes the boundary between aggregate and detailed planning.

Lesson 1 • MRP System Outputs and Action Messages

Interprets MRP action messages and exception reports used by planners. Connects MRP outputs to purchasing, production, and inventory decisions.

Lesson 2 • MRP Record Calculation

Teaches hands-on construction of MRP records for components across multiple BOM levels. Reinforces time-phasing and lot-sizing decisions within MRP.

Lesson 3 • MRP Logic and Inputs

Explains the three core MRP inputs and the netting logic that generates planned orders. Provides the conceptual foundation for all MRP calculations.

Lesson 4 • MRP II and Closed-Loop Planning

Extends MRP to include capacity and financial feedback in a closed-loop system. Prepares students to understand MRP II as the precursor to ERP-based planning.

Lesson 1 • Inventory Replenishment Models

Covers fixed-order-quantity and fixed-period replenishment systems. Students calculate EOQ, reorder points, and order intervals for production scenarios.

Lesson 2 • Safety Stock and Service Level

Teaches statistical methods for setting safety stock to achieve target service levels. Connects demand variability and lead time variability to buffer stock calculations.

Lesson 3 • Inventory Performance and Reduction

Introduces metrics and strategies for measuring and reducing excess inventory. Connects inventory reduction to cash flow, lead time, and operational agility.

Lesson 4 • ABC Analysis and Inventory Prioritisation

Applies Pareto analysis to classify inventory items and differentiate control policies. Enables focused management effort on high-value and high-risk items.

Lesson 1 • Capacity Concepts and Measurement

Defines capacity types, efficiency, and utilisation metrics used in production environments. Establishes the measurement foundation for all capacity planning activities.

Lesson 2 • Capacity Requirements Planning

Covers detailed CRP using routing data and MRP planned orders to generate load profiles. Students identify overloads and underloads at the work centre level.

Lesson 3 • Long-Term Capacity Planning

Addresses strategic capacity decisions including facility expansion and technology investment. Links long-term capacity to business growth and competitive strategy.

Lesson 4 • Capacity Adjustment Strategies

Presents short- and medium-term options for resolving capacity imbalances. Connects capacity decisions to cost, lead time, and customer service outcomes.

Lesson 1 • Multi-Machine and Flow Shop Scheduling

Extends sequencing to multi-machine environments including flow shops and job shops. Students apply Johnson's rule and related techniques.

Lesson 2 • Priority Rules and Sequencing

Covers dispatching rules used to sequence jobs at work centres. Students evaluate rules using performance metrics on single-machine problems.

Lesson 3 • Scheduling Concepts and Objectives

Defines scheduling scope, objectives, and the criteria used to evaluate schedule quality. Distinguishes forward and backward scheduling approaches.

Lesson 4 • Shop Floor Control and Dispatching

Covers real-time execution of schedules through shop floor control systems. Connects planned schedules to actual work order release and tracking.