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Production control: definition & important aspects for buyers
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Production control in a nutshell:
Production control is the operational planning, coordination and monitoring of all manufacturing processes to ensure that products are manufactured on time. It is essential for purchasing, as it forms the basis for needs-based material procurement and optimal warehousing.
Example: An automotive supplier uses production control to plan the production of 10,000 brake components over 4 weeks, whereby the purchasing department calls off the required 30,000 individual parts in three deliveries of 10,000 pieces each every 8 days, staggered according to the production plan.
Contents
Introduction to production control
What is production control?
Production control is a central process in manufacturing that includes the planning, monitoring and control of all production processes. It ensures that resources are used efficiently, production plans are adhered to and goods are manufactured on time and to the required quality. All steps from the procurement of materials to production and delivery are coordinated.
Core elements of production control
Significance for purchasing
Production control plays a decisive role for purchasing, as it has a direct influence on material requirements and procurement times. Efficient production control enables purchasing to create demand forecasts, coordinate just-in-time deliveries and minimize stock levels. This leads to cost savings, improved supplier relationships and greater flexibility in the supply chain.
Implementation of production control
Production control coordinates all processes in production in order to use resources efficiently and manufacture products on time and in the desired quality.
Practical example
Case study: Optimization of production processes in a mechanical engineering company
A medium-sized mechanical engineering company wants to optimize its production processes in order to shorten delivery times and reduce costs.
Steps in production control:
- Analysis of current production data: Recording of throughput times, machine capacities and production quantities.
- Introduction of an ERP system: Implementation of software for central planning and control of all production steps.
- Capacity planning: Optimization of machine utilization through shift planning and maintenance cycles.
- Order management: Prioritization of production orders based on delivery dates and customer requirements.
- Quality control: Integration of quality checks into the production process in order to detect errors at an early stage.
Results:
- Reduction of lead times by 20%: Faster production and delivery to customers.
- Cost savings of 15%: More efficient use of materials and resources.
- Improved product quality: fewer rejects and greater customer satisfaction.
These measures have enabled the company to increase its competitiveness and gain new market share.
Evaluation and strategic findings
✓ Critical success factors
→ Integrated system landscape: Seamless connection between ERP system, production control and purchasing systems for optimal material supply
→ Real-time data availability: continuous flow of information between production and purchasing for precise demand planning
→ Flexible supplier management: building a responsive supplier network for fluctuating production requirements
⚠ Challenges and limitations
→ Inventory optimization: balance between security of supply and minimal warehousing
→ Process synchronization: coordination of production and procurement cycles
→ Quality assurance: guaranteeing consistent material quality with just-in-time deliveries
Future trends and developments:
"The integration of production control and procurement is developing into a strategic competitive advantage."
→ Predictive analytics for demand forecasts
→ IoT-based real-time monitoring of the supply chain
→ AI-supported optimization of order quantities
→ Digital twins for process simulations
◆ Strategic implications
→ Development of integrated planning processes between purchasing and production
→ Development of supplier partnerships with a focus on flexibility and digitalization
→ Investment in employee training for new technologies and processes
Conclusion on production control
Production control is a fundamental success factor for modern companies. It not only efficiently connects production and purchasing, but also optimizes the entire value creation process. By using modern technologies such as AI and IoT as well as integrating real-time data, companies can significantly increase their competitiveness. The key to success lies in the continuous development of processes and close collaboration between all departments involved.
