Course Title:

    Planning for Production Management in Flexible Packaging

    Course Duration:
    • Total Duration: 5 Days
    • Daily Duration: 6 hours per day
    • Format: Combination of lectures, interactive sessions, case studies, and assessments
    Course Objectives:
    • Understand the fundamentals of production planning and control in flexible packaging.
    • Learn to develop effective production schedules and balance supply and demand.
    • Master inventory management, resource allocation, and cost control techniques.
    • Explore the use of technology and automation in improving production management.
    • Gain insights into quality assurance, lean manufacturing, and sustainable production practices.
    Target Audience:
    • Production planners and managers.
    • Operations managers and supervisors.
    • Process engineers and technologists.
    • New hires and experienced employees aiming to improve their production planning skills.
    Day 1: Introduction to Production Planning and Control

    1. Overview of Production Planning in Flexible Packaging:

      • Introduction to production management principles.
      • The role of production planning in ensuring efficient manufacturing.
      • Key components of a production plan (materials, labor, equipment, and timelines).

    2. Understanding Demand and Supply:

      • Analyzing market demand and forecasting production needs.
      • Aligning production schedules with customer orders and market trends.

    3. Capacity Planning:

      • Evaluating production capacity and setting realistic production targets.
      • Planning for capacity utilization, bottlenecks, and production constraints.

    4. Interactive Session:

      • Developing a basic production plan using real-world scenarios.
    Day 2: Production Scheduling and Resource Management

    1. Scheduling Techniques in Production:

      • Types of production schedules (master schedule, daily/weekly schedules, etc.).
      • Balancing production schedules with resource availability and order deadlines.
      • Optimizing workflow to minimize downtime and delays.

    2. Resource Allocation and Workforce Planning:

      • Managing labor, machinery, and material resources effectively.
      • Strategies for cross-training staff and ensuring flexibility in the production process.

    3. Managing Production Changes and Disruptions:

      • Adapting to changes in production schedules due to supply chain issues or equipment breakdowns.
      • Creating contingency plans for unforeseen disruptions.

    4. Group Exercise:

      • Creating and adjusting production schedules for a flexible packaging plant based on simulated conditions.
    Day 3: Inventory Management and Supply Chain Integration

    1. Inventory Management Principles:

      • Understanding inventory control (raw materials, work-in-progress, and finished goods).
      • Just-In-Time (JIT) inventory and its role in reducing waste and improving cash flow.
      • Safety stock and reorder point calculations.

    2. Managing Raw Materials and Supplier Relationships:

      • Coordination with suppliers to ensure timely delivery of materials.
      • Supplier evaluation and management for quality and reliability.

    3. Technology in Inventory and Supply Chain Management:

      • Use of Enterprise Resource Planning (ERP) and Material Requirements Planning (MRP) systems.
      • Automation and digital tools for real-time inventory tracking and optimization.

    4. Case Study:

      • Real-world example of inventory management challenges and solutions in flexible packaging.
    Day 4: Quality Control, Cost Management, and Lean Manufacturing

    1. Quality Control and Assurance in Production:

      • Integrating quality control into the production process.
      • Techniques for minimizing defects and maintaining consistent quality.

    2. Cost Management in Production:

      • Identifying production costs (labor, materials, overhead) and managing cost drivers.
      • Strategies for cost reduction without compromising quality.

    3. Lean Manufacturing and Waste Reduction:

      • Principles of lean manufacturing in reducing waste and improving efficiency.
      • Techniques for streamlining operations, reducing cycle times, and improving throughput.

    4. Hands-On Activity:

      • Applying lean techniques to a simulated production environment.
    Day 5: Technology, Sustainability, and Continuous Improvement

    1. Technology in Production Management:

      • Exploring the role of Industry 4.0 technologies (automation, AI, IoT) in production planning.
      • The use of data analytics and predictive maintenance in improving production efficiency.

    2. Sustainable Production Practices:

      • Incorporating sustainability into production planning (energy-efficient processes, eco-friendly materials).
      • Reducing the environmental impact of flexible packaging manufacturing.

    3. Continuous Improvement and Monitoring:

      • Techniques for monitoring and measuring production performance (KPIs, OEE, etc.).
      • Implementing continuous improvement programs (Kaizen, Six Sigma).

    4. Final Project and Presentations:

      • Participants develop and present a comprehensive production plan for a flexible packaging operation, incorporating scheduling, resource allocation, and quality control.
    Course Materials:
    • Production planning templates and checklists.
    • Case study documents on production management.
    • Sample schedules and inventory management guides.
    • Access to relevant software tools and demo systems.
    • Assessment and feedback forms.
    Evaluation and Feedback:
    • Daily quizzes and practical exercises.
    • Final written and hands-on assessments.
    • Participant feedback forms for course improvement.

    This course is designed to provide participants with essential skills in planning and managing production in flexible packaging, ensuring efficient operations, cost control, and high-quality output while adapting to the latest technologies and sustainability practices.