MPS Development

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MPS Development
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MPS Development

• MPS is the statement of Production Plan by end
  item,datesquantities that is committed to be
  manufactured by the contract.
• MPS seeks to plan and control the impact of
  independent demand on material and capacity.
• A vital link between sales and production.
• Makes possible valid order promises.
• Represents a contract between sales and
  production.
• It should be realistic and achievable

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Objectives

• Maintain the desired level of customer service.
• Makes the best use of resources.
• Keep inventories at the desired level.

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End Item

• A Deliverable unit which might be an A/C or a
  component or a subcomponent or a part that is
  specifically identified in the contract.
• e.gCenter Fuselage, Tailcone,MLG,P-Band Antenna.

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INPUTS

• End Item Delivery Plan(Production Plan)
• Order changes from customer.
• Capacity constraints.
• Estimated Learning Curve Manhour.
• Bill of Material(BOM)
• Assembly Flow.
• Crew Size Optimization.
• SWBS Schedule Work Breakdown Structure.
• Contract Go-Ahead.

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STEPS IN MAKING AN MPS

• Make a preliminary MPS.
• Perform Rough-Cut Capacity Analysis.
• Resolve differences.
• Make the official MPS.

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Rough-Cut Capacity Planning

• Checks whether critical resources are available
  to support the Preliminary Master Schedule.
• Once the MPSs are made,they must be checked
  against the available capacity.
• What are the critical resources?
• Manpower
• FixturesCoji,Assembly Fixture,Autoclave etc.
• Available work place,location.
• Etc.

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Resolving Differences

• If required capacity exceeds the available
  capacity
• Capacity must be increased, or
• Plan must be altered.

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MPS Preparation

• Determine SWBSs,
• Determine the line-move rate,
• Determine the optimum crewsizes,
• Span-time calculations,
• Determine fixture quantity,
• Determine the Assembly Flow,
• Determine end-item completion dates,
• Apply setback in order to get the SWBS start
  dates,

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MPS Preparation

• SWBS-Schedule Work Breakdown Structure
• Some examples
• SWBS X111Mating of Fuselage.
• SWBS X116System InstallationCheckout
• SWBS X162Wing Structural Installation.

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MPS PREPARATION

• Determining the line Move Rate based on end item
  delivery/requirement dates.
• If the delivery rate is4 end item/month
• Considering 20 working day a month
• Line Move Rate is 5 Days

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MPS PREPARATION

• Determining the optimum crewsizes.
• -Analysis of work Areas.
• Availability of work places
• Confined spaces
• -Communicate with the shop people
• -Determine the optimum crew

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MPS PREPARATION

• Calculation of span times for each fixture based
  on learning curve manhours optimum crew sizes.
• Span TimeLearning Curve Budget
  /(CrewsizeWorking Hour Per Day)

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MPS PREPARATION

• Calculation of fixture Quantity.
• Make iterative calculation to ensure below
  equation
• Span TimeltFixture QuantityLine Move Rate
• So Fixture QuantitygtSpan Time/Line Move Rate.
• Example Line Move Rate 5 days
• Learning curve hour 160 manhour
• Optimum crewsize2 technician
• Span Time160/(28)10 mdays
• Fixture Quantitygt10/5
• gt2 (Minimum 2 fixtures)

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MPS Preparation
Item4
Item3
5 Mday
Item2
Item1
8 Mday
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MPS Preparation

• Determination of end item completion dates based
  on line move rate end item delivery dates.
• Applying setback based on calculated span times
  from end item completion dates to generate start
  dates for each SWBS.

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MPS Preparation

• Assembly Flow
• We need Assembly Flow in order to determine the
  SWBS start completion dates.

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MPS Preparation

• Assembly Flow Examples
• A typical Final Assembly Flow
• A component assembly flow

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MPS Preparation

• Case StudyOne of the outstanding A/C
  Manufacturing Companies in Europe needs to buy 48
  Center Wing component in 2008 in order to support
  its Final Assembly which delivers 4 A/C per
  month.After the negotiations Our Company and the
  Customer came to an agreement and signed a
  contract.Deliveries should be accomplished in
  equal quantities in monthly basis starting from
  the beginning of year 2008.

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MPS Preparation

• WE NEED TO PREPARE AN MPS.

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• Getting tecnical information from our customer
  ,we made necessary calculations and analysis
• Determine the Production plan
• Line Move Rate analysis
• Determination of delivery dates.
• Learning Curve analysis.
• Determination of assembly flow.
• Crewsize analysis
• Span time analysis
• Determination of fixture quantities.

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MPS Preparation

• Production Plan

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MPS Preparation

• MPS Delivery Quantities

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MPS Preparation

• Line Move Rate Analysis
• 4 centerwing per month
• Line Move Rate 20/4 5 mdays

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MPS Preparation

• SWBSSchedule Work Breakdown Structure
• Center Box(Coji Operations) X152
• System Operations X151
• AftFront Spar X051
• Trailing Edge X053
• Inboard Flap X056
• Leading Edge X057

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MPS Preparation

• Assembly Flow

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MPS Preparation

• Here well take the first 4 units as a case
• Our Estimation section has informed us that first
  4 units learning curve hours as follows

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MPS Preparation

• Optimum Crewsizes

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MPS Preparation

• Span Time Analysis
• Formula is
• Span TimeManhour/(Crewsize8)
• Based on the assumption that working hour a day
  is 8 hours.

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MPS Preparation

• Calculated span times

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MPS Preparation

• Fixture Analysis
• Fixture QuantitygtSpan Time/Move Rate
• SWBS X152
• Fix.Qtygt20/54
• SWBS X151
• Fix.Qtygt10/52
• SWBS X051
• Fix Qtygt8/52
• SWBS X053
• Fix Qtygt8/5 2
• SWBS X056
• Fix Qtygt10/52
• SWBS x057
• Fix Qtygt8/52

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MPS Preparation

• Delivery DatesAccording to Contract deliveries
  will be done in one shipment at the end of each
  month.(4 items/shipment)
• For January 2008 Shipment

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MPS Preparation

• Determining Completion dates
• First Unit Comp DateDelivery Date Bank Time
• Bank Time is the safety time between delivery
  date and completion date.
• Move rate is other input in calculating the
  remaining units completion dates.

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MPS Preparation

• Determining SWBS Start Dates
• SWBS start dateCompletion Date-Span Time1

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MPS Preparation

• Setbacks are done according to the assembly flow
  chart by using the span times.
• Mdays are converted to Calendar Day by using
  VLOOK-UP function of Excel.
• MPS can be shown either in Microsoft Excel or
  Microsoft Project.

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MPS Preparation
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MPS Preparation

• Mps format in microsoft excel/word

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Royal Jordan Air Force F16 Modification

• SWBS list for F16 Modification

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Royal Jordan Air Force F16 Modification
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Royal Jordan Air Force F16 Modification
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Royal Jordan Air Force F16 Modification
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Status visibility and Control

• Build Crewload charts
• Crewload charts show detail information of each
  task center,
• In operation basis,
• Consist operation hours,daily, schedule,actual
  and earn hour,
• Updated daily/weekly.

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Status visibility and Control
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Status visibility and Control

• Schedule hour is the budget hour of each task
  that is planned in timely manner.
• Earn hour is budget manhour amount of
  accomplished tasks .
• Earn hour of each task should be equal to its
  budget hour when they are done.
• Actual hour is the actual manhour that has been
  spent in order to perform the each task/operation
  ,task center or SWBS.

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Status visibility and Control

• Calculate performance
• PerformanceEarn Hour/Actual Hour
• Performance can be calculated in task center or
  SWBS basis.(Even in operation basis).
• Issue weekly/monthly performance reports.(In SWBS
  /Task Center basis)

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Status visibility and Control

• In order to provide the status visibility we have
  to calculate the completion ratio
• The formula is
• CompleteCompleted Task/Total Task.
• It can be calculated in SWBS and/or Task Center
  basis.

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Status visibility and Control

• If we are doing as planned, this means we are on
  schedule,
• If we have a delay ,this means we are behind of
  schedule,
• If we are doing better than planned ,this means
  we are ahead of schedule.

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Status visibility and Control

• Provide status visibility to Program Management.

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Recovery Plans

• Recovery Plans are needed when incomplete work
  exceeds shops ability to accomplish it within
  its scheduled flow time.
• This is usually caused by
• Unavailability of parts
• Unavailability of manpower.
• Prior work being completed.
• Product not meeting the engineering requirements
• Etc.

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Recovery Plans

• We need to consider
• Overtime
• Second shift
• Additional Manpower
• It might be costly and should be negotiated
  either internally or with the customer.

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We are Done

• THANK YOU !