General information


Subject type: Mandatory

Coordinator: Julián Horrillo Tello

Trimester: Second term

Credits: 6

Teaching staff: 

Francesc Flores Salgado

Skills


Specific skills
  • EC15: Basic knowledge of production and manufacturing systems.

  • EC17: Applied knowledge of business organization.

Transversal competences
  • CT2: That students have the ability to work as members of an interdisciplinary team either as another member, or performing management tasks in order to contribute to developing projects with pragmatism and a sense of responsibility, assuming commitments taking into account the available resources.

Description


Subject framed in the matter of Organization of the Production. The course aims to train students in the basic aspects of the design and management of production systems. Specifically, methods of aggregate planning and stock management in the industrial enterprise are studied. Additionally, the basic aspects of the design of production systems are studied, such as the location of the system, the distribution in the plant and the design of the manufacturing process. All this complemented with the presentation of the main management technologies used in the industrial company.

 

Learning outcomes


At the end of the course the student must be able to:

  • LO1: Understand and analyze the operation of the different areas of a company (EC 17).
  • LO2: Understand the function, costs, and production processes of the company (CE 15).
  • LO3: Use basic techniques and tools for quality and safety management (EC 17).
  • LO4: Use techniques and tools to design a manufacturing plan at its different levels: aggregate planning, manufacturing master plan, and calculation of material needs (MRP) (CE 15).
  • LO5: Understand and use different basic techniques and tools for making business decisions (EC 17).
  • LO6: Evaluate stock management, the market, marketing and the budget (CE 15, CE 17).

Working methodology


The subject consists of 4 weekly hours of face-to-face class and in the classroom (large group), where the theoretical contents will be worked and exercises and problems of a practical nature will be solved; and also consists of laboratory sessions of 2 hour per week up to a total of 20 hours of a practical nature in the computer laboratory (small group).

For each topic of the subject, the student will have a Methodological Guide that will include: Outline of the theoretical contents, proposal of exercises and problems, statements of the related activities, recommended readings, and test of self-evaluation of the objectives of 'learning.

Both theory and laboratory sessions are compulsory, and the latter will be developed by bringing students together in groups of 2 to 6 people, depending on the activity. Each activity will need a previous preparation that will be carried out, a part, in the face-to-face classes in the classroom, and another will have to do it the students in the time of autonomous learning. These activities will be temporarily extended beyond lab hours, and students will be required to complete them during the autonomous learning time.

Whenever it is considered appropriate, it will be made available to students activities of a completely voluntary nature that will help them prepare for work and prepare for those of a compulsory nature.

Contents


Content title 1: Introduction to the Production Organization

  • What is operations management?
  • History of operations management
  • The production function in a global competitive environment
  • Operations strategies:
    • Level Scheduling versus Chase.
    • Push versus Pull

Content title 2: Aggregate planning and programming

  • Aggregate production planning
  • Production master plan
  • Planning techniques: Tabular method (trial and error), Bowman method and Land algorithm.
  • Material Need Planning (MRP)

Content title 3: Stock management

  • Stock valuation
  • Stock management costs
  • Stock management. Monoproduct case: methods based on Wilson's formula
  • Stock management. Multiproduct case
  • Stock management. Methods that incorporate the random factor

Content title 4: Operational research

  • Presentation of the general problem
  • Linear programming: Simplex method
  • Introduction to dynamic programming
  • Application to production planning

Content title 5: Design of production systems

  • Production system design decisions
  • Theory of limitations (OCD)
  • Measurement and analysis of processes
  • Productivity and capacity of productive systems. Bottle necks
  • Location of the production system
  • Distribution in plant: oriented to functions and oriented to product
  • Product design. Portfolio and life cycle management
  • Production and management of innovation
  • Quality management and safety in production systems

Content title 6: Technologies to support production management

  • ICT and competitiveness
  • MRP II: Manufacturing Resources Planning
  • ERP: Enterprise Resource Planning
  • SCM: Supply Chain Management
  • CRM: Customer Relationship Management
  • Human and technological resources

Content title 7: The production and quality plan

  • Objectives of the production plan in the Business Plan
  • Phases in the drafting of the production and quality plan
  • The Quality Plan
  • The ICT Plan

Learning activities


Title of the activity 1: PRODUCTION PLANNING BY THE TABULAR METHOD FROM THE EXPECTED DEMAND. DEPENDENT DEMAND INVENTORY SYSTEM (MRP)

  • DESCRIPTION: Based on a demand forecast, the optimal master plan (MPS) is calculated taking into account the costs of manufacturing in normal hours and overtime and the cost of maintaining the stock. This is the case of restrictions on the capacity of the warehouse. The methods used will be the tabular method (trial and error), the Bowman method, and the Land algorithm
  • SUPPORT MATERIAL: Explanatory dossier provided by the teacher
  • COMPETENCES: CE 15, CT 2
  • EVIDENCE OF LEARNING OUTCOMES: RA2, RA4
  • DELIVERABLES AND LINKS WITH THE EVALUATION: Group report with the optimal solution. This activity represents 5% of the final grade of the subject
  • SPECIFIC OBJECTIVES: At the end of the activity the student must be able to develop a Master Plan of Production and the MRP (planning of the needs of materials) associated from the data of forecast, allotment and deadlines of delivery
  • LABORATORY SESSIONS: 2 sessions

Title of the activity 2: PRODUCTION PLANNING. INDEPENDENT DEMAND INVENTORY SYSTEM

  • DESCRIPTION: Based on the previous activity, a change from manufacturing to marketing is proposed, with a certain policy of prices and service by suppliers, and considering the variability of demand as a parameter of the problem. The design of a stock management policy that takes into account the suppliers' discount policy is required, as well as the need for a security stock based on their delivery times and the variability of demand.
  • SUPPORT MATERIAL: Explanatory dossier provided by the teacher
  • COMPETENCES: CE 15, CT 2
  • EVIDENCE OF LEARNING OUTCOMES: RA2, RA4, RA6
  • DELIVERABLES AND LINKS WITH THE EVALUATION: Group report with the solution of the management of stocks and the placing of orders. This activity represents 5% of the final grade of the subject.
  • SPECIFIC OBJECTIVES: At the end of the activity the student must be able to design production planning for a commercial company, including basic aspects of supplier management, and considering the random component of demand.
  • LABORATORY SESSIONS: 2 sessions

Title of the activity 3: PRODUCTION PLANNING BY MATHEMATICAL PROGRAMMING

  • DESCRIPTION: Activity where the mathematical equations are developed (objective function and constraints) that model a production planning problem. Solution of the model using a computer tool.
  • SUPPORT MATERIAL: Explanatory dossier provided by the teacher
  • COMPETENCES: CE 15, CT 2
  • EVIDENCE OF LEARNING OUTCOMES: RA2, RA4, RA5
  • DELIVERABLES AND LINKS WITH THE EVALUATION: A written group report will be delivered with a description of the objective function, and each of the restrictions, the model file and the solution obtained. This activity represents 5% of the final grade of the subject.
  • SPECIFIC OBJECTIVES: At the end of the activity the student must be able to solve optimally through mathematical programming a production planning problem.
  • LABORATORY SESSIONS: 2 sessions

Title of the activity 4: PRODUCTION AND QUALITY PLAN

  • DESCRIPTION: Develop an operations and quality plan, as part of a business plan, for a proposed industrial product, including the detailed design of the production system, and an ICT plan that includes the technological infrastructure necessary for the production function management.
  • SUPPORT MATERIAL: Explanatory dossier provided by the teacher
  • COMPETENCES: CE 15, CE 17, CT 2
  • EVIDENCE OF LEARNING OUTCOMES: RA1, RA2, RA3, RA4, RA5, RA6
  • DELIVERABLES AND LINKS WITH THE EVALUATION: Written report of the Plan of operations and quality. This activity represents 20% of the final grade of the subject
  • SPECIFIC OBJECTIVES: At the end of the activity the student must be able to know the elements that make up an Operations and Quality Plan, develop a complete Operations and Quality Plan, and design a simple production system.
  • LABORATORY SESSIONS: 4 sessions

Title of the activity 5: EXAMINATION 1

  • DESCRIPTION: Realization of a theoretical examination and of problems of the first 3 subjects of the asignatura.
  • SUPPORT MATERIAL: Bibliography and methodological guides of the subject.
  • COMPETENCES: CE 15, CE 17
  • EVIDENCE OF LEARNING OUTCOMES: RA1, RA2, RA4, RA5, RA6
  • DELIVERABLES AND LINKS WITH THE EVALUATION: Resolution of the test. This activity represents 30% of the final grade of the subject
  • SPECIFIC OBJECTIVES: Eminently evaluative objective of the degree of achievement of theoretical knowledge and its application to practical situations. Collect information for individual summative assessment.

Title of the activity 6: EXAMINATION 2

  • DESCRIPTION: Realization of a theoretical examination and of problems of the subjects 4, 5, 6 and 7 of the asignatura.
  • SUPPORT MATERIAL: Bibliography and methodological guides of the subject.
  • COMPETENCES: CE 15, CE 17
  • EVIDENCE OF LEARNING OUTCOMES: RA2, RA3, RA4, RA5, RA6
  • DELIVERABLES AND LINKS WITH THE EVALUATION: Resolution of the test. This activity represents 35% of the final grade of the subject
  • SPECIFIC OBJECTIVES: Eminently evaluative objective of the degree of achievement of theoretical knowledge and its application to practical situations. Collect information for individual summative assessment.

 

For each activity, teachers will report on the particular rules and conditions that govern them. This information will be communicated in the physical classroom and / or published in the virtual classroom.

One-on-one activities presuppose the student's commitment to carry them out individually. All activities in which the student does not fulfill this commitment regardless of their role (origin or destination) will be considered suspended.

Likewise, the activities to be carried out in groups presuppose the commitment on the part of the students who make it up to carry them out within the group. All activities in which the group has not respected this commitment regardless of its role (origin or destination) will be considered suspended. The responsibility for the results of the work lies with the group, and not with the individuals who make it up. In any case, teachers can, based on the information they have, customize the grade for each member of the group.  

Any undelivered activity will be considered scored with zero points. Failure to attend a laboratory session automatically excludes from the evaluation of the corresponding activity, being considered scored with zero points.

It is optional for teachers to accept or not deliveries outside the deadlines indicated. In the event that these late deliveries are accepted, it is up to the teacher to decide whether to apply a penalty and the amount thereof.

Evaluation system


The final grade is the weighted sum of the grades of the activities:

Activity 1: 5%

Activity 2: 5%

Activity 3: 5%

Activity 4: 20%

Activity 5 (Exam 1): 30%

Activity 6 (Exam 2): 35%

 

Attendance at the theoretical and laboratory sessions, and the delivery of the corresponding reports of activities 1, 2, 3 and 4 is a necessary condition for the evaluation of the subject.

It will be up to the teachers of the subject to decide on the possibility of adding activities that allow the recovery of the suspended activities.

It is compulsory to carry out all the activities to obtain the final grade of the subject. The algorithm for calculating the grade is only applied if the weighted average grade of Activities 5 and 6 is greater than or equal to 4. Otherwise the subject is suspended.

The resit exam only gives the option to pass the subject with a grade of 5, except in the case where the weighted average grade of the first 4 activities is equal to or greater than 8. In this case the final grade will correspond to the weighted average mark of all the activities of the subject (the resit exam corresponds to activities 5 and 6, and its mark must be greater than or equal to 4).

For activities 1 to 4, if the result of their evaluation is not satisfactory, or the teachers consider it opportune, they will be able to summon the members of a group to carry out an individualized evaluation test.

REFERENCES


Basic

DOMÍNGUEZ MACHUCA, JA, et al. (2003). Operations management. Tactical and operational aspects in production and services. Madrid: McGraw Hill.

HEINZER, J .; RENDER, B. (2010). Production and Operations Management. Tactical decisions. Madrid: Prentice-Hall.

HORRILLO, J. (2020). Methodological Guides of the subject of Organization of the Production. Mataró: ESUPT.

Complementary

BOOTHROYD, G .; DEWHURST, P .; NIGHT, W. (2011). Product Design for Manufacture and Assembly. CRC Press.

ELSAYED, EA; BOUCHER, TO (1985). Analysis and Conrtrol of Production Systems. New Jersey: Prentice-Hall.

GAITHER, N .; FRAZIER, G. (2000). Production and Operations Management. Mexico: International Thomson.

VELASCO, J. (2007). Production organization. Plant distributions and improvement of methods and times. Theory and practice. Madrid: Pyramid.