Production Planning and Control is a set of activities that aim to establish, optimize and monitor production processes. The aim is to promote greater understanding of the industry and ensure the correct execution of what was planned.
To understand a little more about the concept, continue reading. In this article we have listed everything you need to know to start implementing the PCP system in your textile industry.
After all, what is Production Planning and Control (PCP)?
Production Planning and Control (PCP) is the concept that refers to the set of techniques, processes and methods that aim to coordinate and monitor industrial production operations.
According to an article by SEBRAE, to better understand what the PCP is, simply understand the concepts that are described in its name. That is, production planning refers to the development, structuring and organization of what you want to happen.
However, there are variables that do not always collaborate with the ideal plan. Such as, for example, changes in consumer behavior, problems with suppliers, broken machines and human errors.
On the other hand,control concerns the action that aims to monitor and deal with these unforeseen events. Here it is possible to apply corrective and preventive actions, such as searching for new suppliers, maintenance of machines, reorganization of teams and employees and investment in training.
In this way, planning aims to document what you want and control is the set of actions that guide the activities so that everything that was idealized and structured happens.
SEBRAE also states that the PCP aims to align and balance the productive sectors and internal and external work. Only in this way will it be possible to obtain full control over production, as all areas will be involved.
Furthermore, the aim is to standardize and manage processes and products and thus facilitate production planning and control. The PCP helps determine the product to be delivered, the ideal quantity to be produced, the definition and supply of materials, in addition to quantifying labor and execution time.
To achieve this, PCP system processes must involve:
- Sales estimate;
- Stock volume of finished products;
- Level of stocks of raw materials and inputs.
- Study of production capacity;
- Product structure;
- Optimal timing of operations.
Benefits of the PCP system
As with any planning process, one of the main benefits will be optimization and productivity. That is, organization and standardization allow the result to be orderly and predictable, in addition to detailing all activities, which guarantees integration between areas and sharing of information. All of this makes it easier to achieve goals.
And with constant monitoring, results will be more consistent and frequent. This is what helps in identifying points of attention to establish order of priorities and correction. This way it will be possible to analyze losses and gains, and avoid waste, be it time, rework, or costs.
Highlighted phrase: Added to this, with the elimination of errors, textile production becomes safer, both in relation to people’s well-being and financial health.
Finally, with efficient communication , employees tend to feel more motivated and engaged. The tip here is to invest in training and bonus policies for employees, according to evaluated data on production efficiency.
Therefore, Production Planning and Control not only contributes to productivity, but also to profitability.
In summary, the advantages are highlighted in the long term. Implementing this system is an investment for future gains, considering that this is a process that values the business strategy.
How to implement?
Production Planning and Control must be repeated frequently, which may be per month, week or days. As it is a system that defines what should be done and what resources to use, it is necessary to establish a schedule with a focus on organization and sequence, to ensure that everything is properly executed.
In general, even if there are no deviations or occurrences, it is necessary to continue controlling and executing the processes. Here, it is recommended to rely on predictability and unpredictability. As previously mentioned, there are factors that affect production and make planning difficult. The difference lies precisely in programming spaces so that, in cases of emergency, production does not suffer as many effects.
The tip here is also to use technology to automate activities and quickly and easily identify patterns that deserve attention. With modern and updated machines , production tends to become more agile and efficient. Digitalization allows the identification of maintenance needs and strategic actions.
Click the button below to download our infographic and have access to 9 maintenance indicators that contribute to monitoring and control.
It is important to have everything recorded and documented in management software, for example. This way, everyone will have access to information about goals, input and output of inputs, cash flow, costs, demands and everything that promotes greater integration.
Decision-making in all areas becomes more assertive when using real data as a basis. Expectations are aligned with production capacity, without exceeding time and expenses.
Finally, define processes well to meet deadlines by prioritizing activities. We also recommend that you apply it in conjunction with the practice of Lean Manufacturing. This way, it will be possible to reduce variability and eliminate repetitive and unnecessary processes.
Applications in the textile industry
The textile industry has become increasingly competitive. According to Abit, there are more than R$4.5 billion, in investment alone, for more than 24.6 thousand formal production units across the country.
Therefore, the textile PCP collaborates with the development of your business and the creation of competitive differences. After all, you will have greater productivity and, consequently, greater quality in the delivery of products to the end customer.
The industrial PCP must involve the factory floor, purchasing, inventory and financial sectors, for example. Generally, it is carried out in 6 steps:
- Demand forecast: with analysis of labor, input and production;
- Production capacity: capacity to meet demand;
- PAP (Aggregate production planning): monthly analysis that helps to stipulate the best strategies;
- PMP (Master Production Programming): guides the best path to execute production;
- PDP (Detailed production scheduling): determines the daily operation and workflow, controlling tasks in real time.
- Production control: monitors activities based on what was planned to identify failures.
Invest in technology
After understanding how to implement Production Planning and Control, it is necessary to invest in technology. Modernization and digitalization contribute to the agility and optimization of processes.
If you want to better understand how innovation and partnership can help in the search for productivity and competitiveness, download our guide for free.
