Description

Introduction:

Production Planning and Control in BAAN IVc4 enables organizations to effectively plan, schedule, and manage manufacturing operations to ensure timely delivery, cost efficiency, and resource optimization. This course provides a deep understanding of how BAAN IVc4 supports the end-to-end production process — from demand forecasting and material planning to work order creation and execution tracking. Participants will learn how to configure production environments, plan capacity, monitor shop floor activities, and analyze performance. Through practical exercises, learners will gain hands-on experience in managing manufacturing workflows using BAAN IVc4’s integrated tools.

Prerequisites:

Participants should have:

• Completed “Introduction to BAAN IVc4: System Overview and Navigation.”

• Basic understanding of manufacturing processes and production cycles.

• Familiarity with master data such as items, BOMs, routings, and work centers.

Table of Contents

1. Overview of Production Planning in BAAN IVc4
   1.1 Role of Production Planning and Control in ERP
   1.2 Integration of Production with Other Modules (Inventory, Procurement, Sales)
   1.3 Key Terminologies: Work Orders, BOM, Routings, and Operations

2. Production Environment Setup
   2.1 Defining Manufacturing Companies and Sites
   2.2 Setting Up Production Parameters and Policies
   2.3 Configuring Work Centers and Resources
   2.4 Managing Calendars and Shifts

3. Bill of Material (BOM) and Routing Management
   3.1 Creating and Maintaining BOMs
   3.2 Managing Multi-Level BOM Structures
   3.3 Defining Routing Operations and Sequences
   3.4 Version Control and Change Management

4. Master Production Scheduling (MPS)
   4.1 Understanding MPS Concepts and Objectives
   4.2 Creating and Maintaining Production Plans
   4.3 Linking Sales Forecasts and Demand Data
   4.4 Evaluating Resource Requirements and Feasibility

5. Material Requirements Planning (MRP)
   5.1 MRP Concepts and Data Flow in BAAN IVc4
   5.2 Running MRP Simulations and Net Change Planning
   5.3 Reviewing Planned Orders and Exception Messages
   5.4 Releasing Planned Orders to Production

6. Work Order Management
   6.1 Creating and Approving Work Orders
   6.2 Material Allocation and Issue to Production
   6.3 Tracking Work Order Progress and Status Updates
   6.4 Managing Order Rework and Cancellations

7. Capacity Planning and Scheduling
   7.1 Defining Capacity and Resource Constraints
   7.2 Finite vs. Infinite Capacity Scheduling
   7.3 Load Analysis and Bottleneck Identification
   7.4 Rescheduling and Capacity Adjustments

8. Shop Floor Control
   8.1 Recording Production Progress and Operation Completion
   8.2 Labor and Machine Time Tracking
   8.3 Monitoring Work-In-Progress (WIP)
   8.4 Reporting Scrap, Rework, and Efficiency

9. Costing and Performance Analysis
   9.1 Tracking Production Costs and Variances
   9.2 Standard vs. Actual Cost Comparisons
   9.3 Generating Production Efficiency Reports
   9.4 Analyzing Productivity and Resource Utilization

10. Integration with Other Modules
    10.1 Production Linkage with Inventory and Procurement
    10.2 Posting Material Movements and Cost Updates to Finance
    10.3 Data Flow to Sales and Distribution Modules
    10.4 Real-Time Reporting and Analytics

11. Practical Exercises and Case Scenarios
    11.1 Creating and Managing BOMs and Routings
    11.2 Running MRP and Generating Work Orders
    11.3 Recording Production Results and Analyzing Efficiency
    11.4 Capacity Adjustment and Shop Floor Optimization

By the end of this course, participants will have a solid understanding of how to manage production planning and control processes using BAAN IVc4. They will be able to plan materials and capacity efficiently, monitor production execution, and analyze manufacturing performance. This course empowers manufacturing and operations professionals to optimize production workflows, reduce delays, and align production activities with business objectives using BAAN IVc4’s integrated ERP capabilities.