Production control

A smoothly functioning production control system is the foundation for a successful manufacturing company. Good planning and control ensure that all processes are optimally coordinated and guarantee efficient and on-time production.

In times of digitalization and Industry 4.0, digital production control has grown enormously in importance. A McKinsey study has shown that companies can achieve significant increases in efficiency through the use of digital technologies and data analysis in production control. By digitally networking machinery in real time, bottlenecks can be identified at an early stage, throughput times can be reduced and overall equipment effectiveness (OEE) can be increased (Source: McKinsey).

Added value: securing competitive advantages

The implementation of modern production planning and control is not a sure-fire success. It requires a careful analysis of existing processes, the selection of suitable technologies, and employee training. Companies that successfully master this challenge can benefit from greater flexibility, shorter delivery times and improved product quality, thus securing competitive advantages.

Production control areas

Production control can be divided into four areas that are closely interlinked:

1) Production planning

This forms the basis of production control. Future production quantities and deadlines are determined.

• Demand: The future demand for products is determined on the basis of customer orders, sales forecasts and stock levels.
• Capacities: Production planning compares this demand with the available capacities of employees, machines and materials.
• Plan: The result is a detailed production plan that defines the quantities to be produced, the start and end dates and the resources required for a specific period.

2) Material Requirements Planning (MRP)

In order for production to run smoothly, all materials must be available at the right time and in the right quantity.

From parts lists to material requirements: Material requirements are determined on the basis of the production plan and the parts lists for the products. The bill of materials lists all the individual parts and assemblies required to manufacture a product.
Inventory management: Material requirements planning compares these requirements with the existing stock levels and order deadlines.
Trigger orders: Orders are triggered for the required materials and material stocks are monitored.

3) Production control

Production control ensures that the production plan is implemented.

• Determine sequence: Production control determines the sequence of operations and allocates the orders to the individual machines and workstations.
• Ensure material flow: Production control monitors the material flow in production and ensures that the required materials are available at the respective workstations on time.
• Monitoring progress: Production control monitors production progress and actively intervenes in the event of disruptions or bottlenecks to ensure that production runs smoothly.

4) Optimizing the production process

Production control is not only responsible for operational control, but also for the continuous improvement of production processes.

• Data analysis: Production data is evaluated in order to identify weak points and optimization potential.
• Initiating improvements: Measures are developed and initiated to increase efficiency, reduce throughput times and improve quality.

What are the challenges and trends in production control?

The increasing complexity of markets, the growing individualization of products and increasing competitive pressure are constantly posing new challenges for production management:

• Globalization and digitalization: manufacturing networks must be increasingly globally and digitally networked.
• Individualization and batch size: Customers want ever more individualized products, which leads to smaller batch sizes and a greater number of variants.
• Sustainability: The reduction of resource consumption and emissions is becoming increasingly important in the industry as a result of sustainability reporting obligations.

What are production control methods?

The choice of the right production control method depends on various factors – such as company size, strategic goals, product portfolio and production environment.

Centralized production control 

All decisions and planning are made at a central location in order to save costs. Centralized production control also enables a high level of transparency and control over the entire process. This method is suitable for companies with a manageable product portfolio and stable production conditions.

Digital production control

Digital production control is essential for companies on their way to becoming a smart factory. By using digital technologies, companies can make their production processes far more efficient, flexible and transparent.

Kanban production control 

With the Kanban principle, production is controlled by the requirements of the subsequent production stage. Signal cards – “kanban” in Japanese – trigger replenishment as soon as a certain material stock level is reached. This avoids overproduction and high stock levels. The Kanban method is characterized by simplicity and efficiency.

How does production control work with FORCAM ENISCO?

With the help of modern software solutions from FORCAM ENISCO or SAP Digital Manufacturing that can be implemented in ERP systems, production processes can be planned and controlled efficiently. In order to categorize different production strategies and processes that are necessary for efficient production, a distinction is made between three factory types according to the number of product variants manufactured (Source: McKinsey):

• One-off production: Production of unique items according to customer requirements (e.g. ships, bridges). The processes usually involve long throughput times, require highly qualified employees and generally result in high production costs.
• Series production: Production of a certain number of almost identical products in series (e.g. cars, computers, furniture). The processes are usually semi-automated and require shorter throughput times than individual production.
• Mass production: Production of large quantities of identical products over a long period of time (e.g. screws, food or products in the chemical or electrical industries). The processes are usually highly automated and the production costs per unit are comparatively low.

Production control with E-MES and MES FLEX

The requirements for all types of production, in particular the increasing demand for product individualization, require particularly flexible and efficient IT solutions. As part of a modular and open-interface platform concept, FORCAM ENISCO’s MES solutions, E-MES and MES FLEX, are specially tailored to the needs of different types of production in discrete manufacturing.

The solutions support both make-to-order production with most product variants as well as series production or customized mass production with less product variance.
For semi-automated or fully automated processes, such as in paint shops or warehouse logistics, E-MES offers complete production control – from system layouts to material flows and resource allocation.

Excursus: What is discrete manufacturing?

Discrete manufacturing is a production process in which individual products are manufactured from various components, which can firstly be counted and secondly broken down into their components. Discrete manufacturing products include cars, airplanes, furniture, smartphones and many more. These products are often manufactured in large quantities, but each item is produced and sold as a separate unit.

In contrast, in process manufacturing (also known as the process industry), mass-produced items are manufactured in batches according to formulas or recipes and cannot be broken down into their original components (chemicals, pharmaceuticals, food and beverage production).