What Is a Production Control System?
A production control system is a system used to manage the various operations of a manufacturing company in an integrated manner.
For example, a production control system is used as an inventory control system to determine how many parts of inventory are left. A production control system can also be used as a process control system or a quality control system.
Production control is the management activity in the manufacturing industry to produce products of a given quality, at an appropriate cost, in the required quantity, and on time. A production control system centralizes information related to production, such as purchasing, orders, inventory, processes, quality, and costs, in order to manage production systematically.
In the past, they existed in a simple form, where products and parts were numbered at the manufacturing site and the progress of the production process was managed. However, it has evolved over time and is now a form of computerized supply chain management for all processes.
Uses of Production Control Systems
Production control systems are used in all areas of the manufacturing industry. From the smallest factory to the largest company with multiple factories, production control systems are used regardless of the size of the company.
However, it is important to note that the production control requirements differ depending on the product, production method, and size of the company. Some production control systems are small enough to perform process control, quality control, and inventory control at the manufacturing site, while others cover a wide range of areas, such as demand forecasting, purchasing management, and cost control.
It is recommended that an optimal production control system be built for each manufacturing site, and it is important for each company to implement a Production Control System that is suited to its needs.
Composition of Production Control Systems
Production control systems work in combination with process control systems and quality control systems. A production control system is an integrated system that brings together several control systems.
The main control systems included in a production control system are:
1. Process Control System
A process control system manages each process at the manufacturing site and checks the progress of each process in order to deliver the final product on time. When a part of the process is subcontracted, the system checks the status of input to and acceptance from the subcontractor.
2. Quality Control System
A quality control system is a system that checks and manages the quality of purchased raw materials, parts, etc. at each stage from receipt to shipment of final products in order to prevent product defects.
3. Inventory Control System
An inventory control system is a system that manages the location of items in a warehouse, records of items being moved in and out of the warehouse, etc., in order to maintain an appropriate level of inventory. Inventory control covers not only the inventory of final products but also the inventory of raw materials and parts used in manufacturing.
Therefore, in addition to inventory information in the warehouse, it is necessary to integrate information on material purchases, manufacturing processes, sales, etc. for inventory control.
4. Demand Forecasting System
A demand forecasting system is a system that forecasts demand using a model appropriate for the product based on past performance. It helps to optimize inventory and allocate resources appropriately.
Other Information on Production Control System
Applications of Production Control Systems
In addition to the systems mentioned above, a production control system may also include a purchasing management system, a cost management system, and a sales management system. By integrating all of these systems with the Production Control System, proper management at each stage can be achieved.
Purchasing Management System
A purchasing control system is a system for purchasing materials and other items for products at the production site. In fabless companies that do not have factories, not only materials but also products themselves may be purchased.
Cost Management System
A cost management system is a system that performs management such as cost calculation, analysis, and simulation. The purpose of implementing a cost management system is to understand and analyze costs, maximize profits, and respond to risks through optimal cost management.
Sales Management System
A sales management system is a system by which a company or factory receives orders and controls the flow of money and products. It can be described as a system whose purpose is to sell products and earn money.