STUDY OF PLANNING AND CONTROL ASPECTS IN MANUFACTURING

Abstract

Production Planning and Control (PPC) is a critical component of a Make-to-Order (MTO) system that ensures production processes are coordinated to fulfil specific client demands while optimising resources and adhering to delivery deadlines. PPC in MTO settings is different from traditional mass production systems since each order is distinct and frequently customised. Make to Order (MTO) is increasingly important in order to satisfy constantly evolving client needs. The percentage of MTO enterprises has increased in tandem with the growing demand for customised goods. The MTO idea has been applied by numerous industries and product categories, giving them a competitive advantage in sustainable production. Make To Order (MTO) is a manufacturing management strategy that helps decrease overproduction and item waste, promotes sustainable manufacturing, and boosts overall organisational competitiveness. Manufacturing companies are facing increased competition in which customer requirements are more demanding in terms of flexibility, quality, cost, and response time. In light of these conditions, MTOs have drawn the attention of researchers and practitioners who see the benefits of reduced finished product inventory levels, high levels of customisation, and the ability to quickly adapt to changing customer behaviour. These systems not only meet the needs for a wide range of products but also make it possible to deliver products on time. Given this need for research, the current study focuses on the critical success factors, and implementation strategies for make to order manufacturing systems. The literature review reveals that businesses are reluctant to embrace new technologies and aren't stepping up to switch from make-to-stock to make-to-order production processes in response to the demands of expanding markets. In order to address this study gap, a thorough evaluation of the literature is done on the critical success factors of MTO. The identification of vii critical success factors and implementation strategies for Make to order manufacturing systems has been the subject of research; nevertheless, conceptual papers have received a greater amount of attention than theory-building articles. Furthermore, the Indian market scenario has received less research. Make to Order as a manufacturing strategy is a rapidly developing idea in India, and the critical success factors of Make to Order that propel the present market were thoroughly investigated. This study aims to rank the various approaches to implementing make-to-order manufacturing systems and identify and prioritize the critical success factors (CSF) that can impact its adoption. Eighteen critical success factors were grouped into six categories and three implementation strategies ranked based on inputs from industry experts. The present research suggests an integrated methodology that employs the Analytic Hierarchy Process (AHP) to prioritise Critical Success Factors and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) to rank the implementation strategies. The research indicates that the most effective way to execute MTO would be through a customer-centric approach. Building a sustainability model using an MTO production system is the aim of this research. Sustainable manufacturing has piqued the interest of policymakers, producers, and society at large in an effort to reduce harmful environmental effects. Through this method, the researchers are looking into a number of elements related to Configurable Product, Customer Need, Emerging Technology, Information Technology, Market Performance, and Organisation Readiness. PLS-SEM (SMART PLS 4), or the Partial Least Squares technique to structural equation modelling, has been used to create the model and ascertain the degree of relationship between items based on the replies to structured questionnaires. The empirical results show that each strategy significantly affects the MTO production system. Competitive Advantage acts as a mediator for the relationship between MTO and Sustainable manufacturing. The viii current literature on sustainable manufacturing initiatives has been extended and improved by these findings, and give researchers a fresh angle from which to further explore this idea. The manufacturing approach chosen for the deployment of Make To Order was verified by the research using the multiple case study method. With the aid of several case studies, this study sought to validate the earlier critical success factors. PPC expert, Sales and Marketing expert, IT expert, Head of operations, Product expert, Design Expert, and Business strategy expert from two Indian manufacturing companies were interviewed in depth. The case companies vary widely in terms of their ownership, size, and target markets. Identifying challenges and suggesting strategies to improve make to order implementation for competitive advantage are presented in industries attempting to apply it. This study will help managers better understand the critical areas where greater emphasis is needed when considering a shift from make to stock to make to order. Identifying and prioritization of critical success factors and implementation strategies for MTO will assist managers and decision-makers in focusing on a few key drivers that will support in the transition from make to stock to make to order. The case studies will help practitioners to understand the critical success factors were practically used by certain companies for MTO implementation. A clear image of MTO as a business strategy is provided by the difficulties encountered by the case firms and the organisational lessons learned as well as the conclusion. This approach will assist managers in determining the necessary elements for the transition from make to stock to make to order.