The Materials Controller’s roles and responsibility is one of the key functions in the overall supply chain, and managed effectively will result in meeting business objectives and assuring satisfies customers.

·         Best practices and methodologies of the modern manufacturing theories in both continuous and batch operations

·         Defining roles and responsibilities o an effective Materials Controller

·         The importance of materials Controller in both manufacturing and the service sector of the company

·         Defining systems to assure to become a low quality supplier of goods and services

This Course will address the principles of production planning and inventory control using the best practices in modern manufacturing theories and practices. Participants will gain greater appreciation to the benefits of positioning their operations and optimize the value from the supply chain.

Participants will be exposed to key manufacturing principles such as:

·         The Supply Chain Management

·         Planning and controlling inventory levels

·         Physical control of inventories

·         Elements of material control

·         Material Requirement Planning

·         Manufacturing Resource Planning principles

·         Sales of Demand management

·         Master scheduling management methods

·         Capacity Requirements Planning

·         Operations execution and control

·         The manpower and resource planning

Senior Production, Maintenance and Operations Managers, Line Production Supervisors and Production Engineers, materials and Supply Chain professionals, plant superintendents, inventory planners, master planners, master schedulers, production and maintenance first line supervisors. In addition accounting and financial personnel, Purchasing Agents and those involved with implementing Just-In-Time and Manufacturing Resource Planning initiatives will benefit greatly.

Day I : Business Concepts and Planning

·         Time line for emerging new technologies in manufacturing

·         Key manufacturing Questions

·         Concept of Supply Chain Management

·         Classification of Operations

·         Business Planning Cycle

Day II : MRP – Materials Requirement Planning

·         Materials Structure Tree

·         Gross Materials Requirement Planning

·         Net Materials Requirement Planning

·         Master Production Scheduling Overview

·         Bill of Materials

·         Key MRP Activities

·         MRP Integration Issues

Day III: MRP II – Manufacturing Resource Planning

·         Sales & Operations Planning

·         Demand management & Forecasting

·         Capacity Planning

·         Master production Scheduling

Sales and Operations Planning

·         Anatomy of S&OP process

·         Sales and Operations Planning Activities

·         Integration – issues & Challenges

·         S&OP measurements

Day IV : Demand Management & Forecasting

·         Demand management

·         Forecasting techniques

·         Resource Planning

·         Master Scheduling

·         Rough Cut capacity Planning

·         Capacity Requirements Planning

Capacity Planning

·         RCCP – Rough Cur Capacity Planning

·         CRP – Capacity Requirement Planning

·         Plant Scheduling

·         Kanban integration

·         Supplier Scheduling

·         JIT Concepts

Day V : Master Production Scheduling

·         Supply –Side Forces

·         Demand-Side Forces

·         Lead Time

·         Production Forecast

·         Manpower Planning

·         Special Customers Specifications – SCS

·         Master Scheduling Activities

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session