Fundamentals of Manufacturing for an ERP is a Course released on 26th November 2020, aimed at freshers aspiring to learn and Fundamentals of Manufacturing Functions. The Course than was upgraded on regular intervals till date (18-Jan-2022)
Read more
Fundamentals of Manufacturing for an ERP is a Course released on 26th November 2020, aimed at freshers aspiring to learn and Fundamentals of Manufacturing Functions. The Course than was upgraded on regular intervals till date (18-Jan-2022)
Fundamentals of Manufacturing for an ERP is a Course released on 26th November 2020, aimed at freshers aspiring to learn and Fundamentals of Manufacturing Functions. The Course than was upgraded on regular intervals till date (18-Jan-2022)
In typical manufacturing organization you may be directly part of manufacturing the Products of your organization. Or you may be dealing with Manufacturing unit while performing functions such as Sales, Marketing, Procurement, Planning, Design, Accounting, Finance, Store keeping and Services. In all your dealings you might be wondering on some of the terms and practices that you might be hearing in the conversations with your Manufacturing counterparts.
You as a Store keeper deal with issuing materials and may realize certain material are issued as a set because they are all used to make certain product. At times, you will be seeing alternative items issued in place of the items in the Material list against the work order for which you are issuing the material. At times, you see some material are not immediately requested even if they are in the Material list of Work order. This is probably because they are needed only in later steps of manufacturing. You will pick a few things about manufacturing and miss many.
As a Sales person you will be wondering why an order for big quantity from customer can not be fulfilled at the given dates. Why cant this order be still taken and fulfil by engaging more people to complete on time. You will be disappointed for the delay of Cash Flow when the Planner or Plant manager firmly confirm the order of such size can be delivered only at a later date. You may really want to know what are those constraints which can not let the Production Plant deliver the order on the date you wanted even with adding man power.
Even as a Lathe Machine expert in the Manufacturing Department, you might be wondering on many aspects on what is impact of your work on the end product and why certain scheduling actions on your piece of work, are not clear to you.
This kind of "missing knowledge" or "gaps of knowledge" is quite common for all interfacing functions of Manufacturing, as well as the function Manufacturing itself. Every one of you know a little bit on Manufacturing not all the basics. If any of you want to pick up Manufacturing as your add-on Skill or full time career, you may first want to get to the basics.
Any career aspirant a new comer from the college or a non-manufacturing SME want to get in to Manufacturing domain, the basics will be the starting point. And basics are the foundation based on which you grow.
eBodhisathva Solution made the course with above kind of professionals and starters.
This course is fully focused on explaining the very fundamentals of Manufacturing, with detailed illustrations where possible.
The examples used in the Course are not very usual examples that you may see from public information. Lot of effort is spent to include more realistic and close to real examples in the Organization.
To make the explanation very appealing, lot of graphics and animations are applied appropriately.
The aspirants of ERP career, IT consultants, Professionals in other domains of Manufacturing industry and Engineering students may take this as a starting point before going in depth to specialized topics within Manufacturing.
The Course is structured as below:
Introduction to Manufacturing
Bill of Material
Routing
Types of Manufacturing
Discrete Job Shop
Repetitive Manufacturing
Assemble to Order Manufacturing
Project Manufacturing
Process Manufacturing
Just in Time (JIT)
Inventory types
Inventory types according to how they are used
Relevance in multiple manufacturing environment (for each inventory type)
Inventory Classification
ABC, Classification
Fast and Slow Moving
How Inventory Management policies are determined for each type
Order Review methods
Quantity Based review methods (Re-Order Point, POQ, Visual reviews etc)
Demand and Quantity based review methods (TPOP and MRP etc)
Briefing on Planning Functions
(Netting requirements,
Scheduling methods and
Lot sizing)
Key information required for Planning
Inventory Data (Item, Planning and Stock info)
Master Scheduling Data (MPS, Plg Horizon, MPS feasibility)
Engineering Data (BOM, Routing, Mfg Instructions)
Planning Hierarchy
Mission Statement
Corporate and Business Strategy
Supporting Strategies (Marketing, Financial,Engineering, Manufacturing etc)
Practice Kits
Quizs
The Course has supporting Off-line reading material in the form of eBooks for most of the topics covered.
The Course included exercises for Practical understanding of the concepts, wherever applicable.
The Course is associated Quizs for students to refresh their understanding during attending course
This course will be Continuously refined according to the feedback received. The enhancements will be included in the course for no extra-cost for the students already enrolled as well as for new students.
The audience are requested to make a note that the course will be a bit slow keeping the target audience (Novices)in view. Any in-depth understanding needs further efforts on top of attending this course.
What's inside
Learning objectives
- What is manufacturing
- Types of manufacturing at a glance
- Bill of material & routing
- Discrete job shop
- Repetitive manufacturing
- Assemble to order manufacturing
- Project manufacturing
- Process manufacturing
- Just in time (jit)
- Inventory management: inventory classification
- Order review methods: quantity based order review methods (rop, poq . hybrid, visual etc)
- Order review methods: demand and quantity based order review methods (tpop and mrp)
- What is manufacturing
- Types of manufacturing at a glance
- Bill of material & routing
- Discrete job shop
- Repetitive manufacturing
- Assemble to order manufacturing
- Project manufacturing
- Process manufacturing
- Just in time (jit)
- Inventory management: inventory classification
- Order review methods: quantity based order review methods (rop, poq . hybrid, visual etc)
- Order review methods: demand and quantity based order review methods (tpop and mrp)
Syllabus
The students will get basic idea of manufacturing terms and will get some understanding on what topics are going to be covered in the rest of course
Read more
Syllabus
This lecture briefs the course content
This lecture briefly explains the section contents.
The section starts with Manufacturing definition by going through some examples, observations on the examples followed by attempt to define manufacturing in terms of technical and economical aspects.
It also helps understand a few terms involved in Manufacturing process.
A typical Manufacturing Process at a high level is narrated for basic understanding.
The session ends with a Summary and recap.
Through a few examples and discussions, an attempt is made to define Manufacturing in Technical and Commercial aspects. Finally the standard definition from APICS is presented.
The transformation from Raw material to Finished product and the state of work in progress before the raw material reaches the state of finished product is explained. A Few important terms are explained as well.
This lecture helps you understand bill of material through a couple of examples and illustrations. This will be followed by Standard Definition given by APICS, USA.
The lecture briefs the importance of Whereused BOM report which provides all the parents of a Component. It also covers the Pegging report which shows the parent items impacted by any issue of the component.
This lecture briefs on how each department such as Design, Manufacturing / Production, Sales, Product Costing and Service teams use BOM as important reference.
This lecture is to summarize the content covered on Bill of Material and conclude the section.
This lecture briefs the contents of the short course on Routing.
This lecture briefly touches various popular manufacturing types in practice and brief highlights of each type of manufacturing in terms of
Pros and cons
On what circumstances the practices are adopted
What kind of metrics are applicable to each type of manufacturing
Planning and scheduling approach in each case
This lecture briefly explains the Discrete Job Shop Manufacturing. The characteristics of a typical job shop are explained with examples and scenarios.
In this lesson a brief of Repetitive Manufacturing is given in terms of salient features of this manufacturing method.
In this lesson a simple illustration on how Products of minor variations grouped as Mixed Model are manufactured in Repetitive Manufacturing layouts.
The lecture briefly covers Process Manufacturing. The explanation is done in the form of an illustration (Making Flour from grains). This is followed by running through various parameters and comparing between Discrete and Process Manufacturing scenarios. The session concludes with Summary of overall understanding
This lecture briefs about Just in Time philosophy. Most of the JIT principles are explained one by one with examples and illustrations where applicable.
For making any value adding item you will be using some ingredients and tools to make the same. These ingredients are not always purchased just before making the item. When the time to make the item has to be short, you can not spend time in procuring the items. For striking a balance between holding large quantities of Inventory and keeping low cost of inventory, you need to follow inventory management principles. Inventory classification helps you determine where to have tight controls. This lesson helps you appreciate the importance of Inventory and definition of inventory.
The lesson is about why do we need inventory management. Major drivers for Inventory Management in terms of Customer service, On time delivery and costs are discussed.
In this lesson, you will briefly run through multiple manufacturing environment before discussing list of Inventory types based on the way the inventory is used. The reason for covering basics of prominent manufacturing environments is to relate the way inventory policies are impacted by these environments such as Make to Stock, Make to Order, Assemble to Order, Project Manufacturing and Process Manufacturing etc.
Multiple types of Inventory according to the usage and the accounting principles are discussed briefly.
Major types of inventory such as Raw Material / Component Parts, Work in Progress, Semi-Finished Goods, Finished Goods, Cosigned Stock and MRO are briefed with examples.
A few other types of inventory such as Excess Inventory, Obsolete Inventory and Non-Conforming Inventory; which do not fall in traditional inventory classification are also discussed.
This lesson covers definition of raw material followed by it's significance in make to stock, make to order and assemble to order environments.
Inventory type Finished Product is relative to the organization. Finished product for you can be raw material for another organization that purchases your product for use in manufacturing of their product. Finished product is the material that you manufacture to sell. Once sold the material will be called "Sold" Item. While on it's way to Customer it is called "In Transit" Inventory. Depending on agreement this same material is called "Consigned Inventory" when these finished items are in possession of customer but the payment is made according to how much of the inventory is consumed by customer.
This lesson discussed finished material and it's demand management, Order methods, fulfilment and storage methods etc in multiple Manufacturing environment such as Make to Order, Assemble to Order and Make to Stock.
Consignment inventory is a special type of Inventory. Unlike Finished Item, Semi-finished Item, WIP Item and Raw Material which are quite relevant to the state of the material at certain stage in the Manufacturing Process, Consigned inventory is a state according to one type of Procurement agreement. The Finished items of one Organization are stored in customer's warehouse for an agreed period. The payment happens based on consumption of inventory at customer (called Consignee) in certain period. Both Consignee and Supplier organization are benefited in different ways in this arrangement.
There are a few types of inventory which are not traditionally categorized Inventory types. But they are briefed here to indicate their significance and to explain how such types of inventory are handled in Manufacturing environment.
The topics covered in this lesson are inventory types excess inventory, obsolete inventory and non-conformance inventory.
Agenda of course within the section Order Review and Planning Methods: Context is covered
Most traditional Order review and planning was on the basis of what is called Order point. Also called as Re-Order Point this was the first inventory planning method which was based on regular review of stock levels and re-filling the inventory at certain point of stock level. This lesson helps the students get a few basics of this method and how the method was improved over a period of time.
This lesson gives a briefing on Periodic review system which addressed some of the setbacks in Order point review method. Apart from explaining the Periodic review system, a snapshot of comparison between Order point, Replenish to Maximum inventory and Periodic review system is provided.
The best of Order point and periodic review system are picked to arrive at a few hybrid order review methods. A couple of such methods are discussed in this lesson.
There were many visual review methods which do not need specific measurement effort to determine the timing of placing fulfilment order. Such review methods such as Two Bin System and a few others are briefed in this lesson.
The section was concluded with a recap and a few meaningful conclusions.
Traffic lights
Save this course
Save
Reviews summary
Manufacturing fundamentals for erp beginners
Uses practical, realistic examples and illustrations.
Concepts are explained in an easy-to-understand way.
Provides a strong base in manufacturing fundamentals.
Content is highly relevant for ERP users and consultants.
Activities
Review Bill of Materials (BOM) Concepts
Show steps
Reinforce understanding of BOM structures and their importance in manufacturing before starting the course.
Browse courses on
Bill of Materials
Show steps
-
Read articles or watch videos explaining different BOM types (EBOM, PBOM, etc.).
-
Create a simple BOM for a familiar product (e.g., a bicycle or a desk).
-
Identify the key components and their relationships in your BOM.
Understand Manufacturing Lead Time Components
Show steps
Solidify understanding of the different components of manufacturing lead time to better grasp production scheduling concepts.
Show steps
-
Review definitions of setup time, run time, wait time, move time, and queue time.
-
Consider how each component affects overall production time.
-
Think about ways to reduce each type of lead time.
Read 'Orlicky's Material Requirements Planning'
Show steps
Gain a deeper understanding of MRP concepts, which are crucial for understanding ERP systems in manufacturing.
View
Orlicky's Material Requirements Planning
on Amazon
Show steps
-
Read the book chapter by chapter, taking notes on key concepts.
-
Relate the concepts to the course materials and real-world manufacturing scenarios.
-
Consider how MRP principles are implemented in ERP systems like SAP.
Four other activities
Expand to see all activities and additional details
Show all seven activities
Create a Presentation on Types of Manufacturing
Show steps
Solidify understanding of different manufacturing types by creating a presentation that explains their characteristics, advantages, and disadvantages.
Show steps
-
Choose 3-4 manufacturing types (e.g., discrete, repetitive, process, assemble-to-order).
-
Research each type and gather information on its key features and applications.
-
Create a presentation with clear explanations and visuals.
-
Present your findings to a peer or record a video presentation.
Review 'Production and Operations Management' by Stevenson
Show steps
Broaden understanding of production and operations management principles, providing context for manufacturing within an ERP system.
View
Operations Management
on Amazon
Show steps
-
Read relevant chapters on inventory management, scheduling, and capacity planning.
-
Relate the concepts to the manufacturing types discussed in the course.
-
Consider how these principles are implemented and managed within an ERP system.
Design a Manufacturing Process Flow
Show steps
Apply knowledge of manufacturing types and processes by designing a process flow for a specific product.
Show steps
-
Choose a product (e.g., a smartphone, a chair, or a food item).
-
Determine the appropriate manufacturing type for the product.
-
Map out the steps involved in the manufacturing process, from raw materials to finished goods.
-
Identify key decision points and potential bottlenecks in the process.
-
Document your process flow using a flowchart or other visual representation.
Develop an Inventory Classification System
Show steps
Apply inventory management principles by developing an ABC classification system for a hypothetical manufacturing company.
Show steps
-
Gather data on a set of inventory items (e.g., annual usage, unit cost).
-
Calculate the annual value of each item (usage x unit cost).
-
Rank the items by annual value and classify them into A, B, and C categories.
-
Develop inventory management policies for each category (e.g., safety stock levels, order quantities).
Review Bill of Materials (BOM) Concepts
Show steps
Reinforce understanding of BOM structures and their importance in manufacturing before starting the course.
Browse courses on
Bill of Materials
Show steps
- Read articles or watch videos explaining different BOM types (EBOM, PBOM, etc.).
- Create a simple BOM for a familiar product (e.g., a bicycle or a desk).
- Identify the key components and their relationships in your BOM.
Understand Manufacturing Lead Time Components
Show steps
Solidify understanding of the different components of manufacturing lead time to better grasp production scheduling concepts.
Show steps
- Review definitions of setup time, run time, wait time, move time, and queue time.
- Consider how each component affects overall production time.
- Think about ways to reduce each type of lead time.
Read 'Orlicky's Material Requirements Planning'
Show steps
Gain a deeper understanding of MRP concepts, which are crucial for understanding ERP systems in manufacturing.
View
Orlicky's Material Requirements Planning
on Amazon
Show steps
- Read the book chapter by chapter, taking notes on key concepts.
- Relate the concepts to the course materials and real-world manufacturing scenarios.
- Consider how MRP principles are implemented in ERP systems like SAP.
Create a Presentation on Types of Manufacturing
Show steps
Solidify understanding of different manufacturing types by creating a presentation that explains their characteristics, advantages, and disadvantages.
Show steps
- Choose 3-4 manufacturing types (e.g., discrete, repetitive, process, assemble-to-order).
- Research each type and gather information on its key features and applications.
- Create a presentation with clear explanations and visuals.
- Present your findings to a peer or record a video presentation.
Review 'Production and Operations Management' by Stevenson
Show steps
Broaden understanding of production and operations management principles, providing context for manufacturing within an ERP system.
View
Operations Management
on Amazon
Show steps
- Read relevant chapters on inventory management, scheduling, and capacity planning.
- Relate the concepts to the manufacturing types discussed in the course.
- Consider how these principles are implemented and managed within an ERP system.
Design a Manufacturing Process Flow
Show steps
Apply knowledge of manufacturing types and processes by designing a process flow for a specific product.
Show steps
- Choose a product (e.g., a smartphone, a chair, or a food item).
- Determine the appropriate manufacturing type for the product.
- Map out the steps involved in the manufacturing process, from raw materials to finished goods.
- Identify key decision points and potential bottlenecks in the process.
- Document your process flow using a flowchart or other visual representation.
Develop an Inventory Classification System
Show steps
Apply inventory management principles by developing an ABC classification system for a hypothetical manufacturing company.
Show steps
- Gather data on a set of inventory items (e.g., annual usage, unit cost).
- Calculate the annual value of each item (usage x unit cost).
- Rank the items by annual value and classify them into A, B, and C categories.
- Develop inventory management policies for each category (e.g., safety stock levels, order quantities).
Career center
Manufacturing Planner
Production Supervisor
Supply Chain Analyst
Materials Manager
ERP Consultant
Inventory Specialist
Manufacturing Engineer
Operations Analyst
Production Controller
Logistics Coordinator
Sales Representative
Project Manager
Quality Assurance Analyst
Financial Analyst
Business Analyst
Reading list
Share
Similar courses
OpenCourser helps millions of learners each year. People visit us to learn workspace skills, ace their exams, and nurture their curiosity.
Our extensive catalog contains over 50,000 courses and twice as many books. Browse by search, by topic, or even by career interests. We'll match you to the right resources quickly.
Find this site helpful? Tell a friend about us.
We're supported by our community of learners. When you purchase or subscribe to courses and programs or purchase books, we may earn a commission from our partners.
Your purchases help us maintain our catalog and keep our servers humming without ads.
Thank you for supporting OpenCourser.
