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8/9/2019 Session 6 & 7 Production Planning & Control
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session 6
PRODUCTION
PLANNING & CONTROL
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Planning includes the consideration of all inputvariables so that the predetermined output goals.can be achieved
Control means to take a remedial action to prevent
the variation of actual output from the desired.one
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roduction Planning -is a pre production activitythat involves determination of optimal production
, ,schedule sequence of operation economic batch,quantity optimal job machine assignment and
.dispatching priorities for sequencing of jobs It also involves the determination andevaluation of the other inputs such as manpower
.and money
Control is a complementary activity to the,production planning which keeps track of theoperations that are being performed during the
.production phase
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roduction Planning , -implies formulation coordination and determination of activities in a
manufacturing system necessary for the.accomplishment of desired objectives
roduction Controlis the process of maintaining abalance between various activities evolved during
production planning providing most effective and.efficient utilization of resources
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roduction Planning
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:Process of Production Planning Defining Objectives Setting priorities to attain the objectives ,Analyzing the internal external environment Determining attainable targets Determining the inputs required for
.achieving the targets
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Functions of Production Planning:
Production Selection and Design: Ensure that the suitable kind ofproduct is selected which fulfils
.the market demands Ensures that design of the product is
according to the customer.requirements
Process Selection and Planning: To select the appropriate process that
includes selection of right kind of, ,technology machines material
handling systems and automation for.the production of a product Allows you to perform efficient process
.planning Facility Location:
Helps to choose a proper location for aplant in order to minimize the costs
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Facility Layout and Materials Handling:
To facilitate the transfer of materialand processing of a product in themost efficient manner through the
shortest possible distance with.minimum time wastage
Capacity Planning: Helps to determine how much resource
should be kept to meet the current.market demand
Procedure Planning: Allows you to ensure that the product
being produced as per the specified.quality standard
Estimating: To determine the quantity of the
products and cost associated in the
production of the required quantityof product with the help of sales
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Routing:
Helps determine the proper sequence ofoperations involved in the production.process to meet the production objectives
Process of determining operation sequence isknown as routing.
,For performing routing a route sheet is.prepared
Following information is stored in a route:sheet
Required operations and their propersequence
Machine to production requirements Approximate set up time and operation
.time required per piece of product Tools and fixtures required for
.manufacturing the products
Raw material specifications
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Scheduling:
Helps in laying down time required formanufacturing a product and time requiredfor a product to move form one machine to.other
:Following are the objectives Avoid improper utilization of time
among departments and work centers Optimum utilization of labor and the
output is produced within the.prescribe time
Loading:
Helps determine which job should be assignedto which machine to obtain maximum and.desired output
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roduction Control
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Functions of Production Control: Success of anenterprise greatly depends on the performance of
.its production control department , ,Provision of raw material equipment machines
.and labor To organize production schedule in conformity
.with the demand forecasts Resources are used in the best possible
manner in such a way that the cost ofproduction is minimized and delivery date
.is maintained To ensure regular and timely supply of raw
material at the desired place and of
prescribed quality and quantity to avoid.delays in production -To perform inspection of semi finished and
.finished goods and use quality control It is responsible for product design and
.development
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Importance of Production Control: Reduces cost of production by minimizingwastage of material and economic
.utilization of resources Leads to lower investment by means of
efficient and balanced utilization of.resources Promotes employee morale by avoiding all
.sorts of bottlenecks .Enhances customer satisfaction and confidence
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roduction PlanningControl
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Objectives of Production Planning and Control:
Effectiveness : production of right of goods Maximizing output : production of maximumgoods
Quality control : meet quality specifications Minimizing throughput time: reducing waiting
time and idle time Capacity Utilization: manpower and machine isfully utilized
Minimizing cost : cost of producing goods is.minimized
Maximizing Profit: maximize profit withminimize cost Minimizing throughput: minimum time to
production cycle Maintaining Inventory level: optimum level of
stock is maintained
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Maintaining the performance: proper standards
are maintained by comparing the actual.results with the planned results Capacity planning: proper planning for the
future requirements Reducing bottlenecks: bottlenecks are removed
.from all the stages of production Preparing production schedules: timely
production is made Establishing routes and schedules: optimum
,utilization of materials labor and.equipments by preparing schedules for work
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To ensure quality goods in requiredquantities in the required delivery
.schedule
.To ensure production of quality products To establish routes and schedules for work
that will ensure optimum utilization of.resources
To provide the means for ensuring theoperation of the plant in accordance with.these plans
-To minimize the product though put time or.production cycle time
.To maintain optimum inventory levels To maintain flexibility in manufacturing
.operations -To co ordinate between labor and machines
.and various supporting departments To plan for plant capacities for future
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Determining the nature and amount of various
input factors to manufacture the desired.output - ,To co ordinate labor machines and equipment
.in the most effective and economic manner Establishing targets and checking these
.against performance
Ensuring smooth flow of material by, ,eliminating bottlenecks if any in
.production .Utilization of under employed resources To manufacture the desired output of right
.quality and quantity at right time
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LANNING AND CONTROL DEPARTMENT
Product structure
Manufacturing Documents
Assembled Products
Finished Goods
R & D Department(Product Design)
Production Planning & Control Department
Manufacturing Departments
-Fabrication-Assembly
Final Inspection & Acceptance testing
Packing & dispatching of finished goods
Distribution to customer through channels of distribution
Inspection & Quality Control
Industrial Engineering DepartmentMarketing Department
Purchase Dept. and Stores Dept.
Maintenance Dept.
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:ypes of Production Processes.1 Process Production.2 Mass and Flow Production.3 Batch Production
.4
Jobbing Production
.5 Project Production
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.1 PROCESS PRODUCTION: A system for production where a similar product is
.produced continuously in large quantities : , ,Example steel cement sugar
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Production planning and control in Process Industry:
n PPC .in process industry is relatively simple.Routing is automatic and uniformn Standard processes and specialized
.equipments are usedn As the products are standardized and goods
,are produced to stock and sell scheduling.is easyn Departmental schedules are derived from
.master production schedulesn PPC in process industry is to maintain a
continuous and uniform flow of work atthe predetermined rate in order to
utilize the plant and equipment fully and.to complete the production in time
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Characteristics of PPC in Process Industry:
.I Sound organizational structure with mechanism forproper delegation of authority and fixation of.responsibility at all levels
.II Information feed back system should provide- -reliable and up to date information to all
.persons carrying out PPC functions.III ,Trained personnel for using the special tools
.equipments and manufacturing processes.IV Flexibility to accommodate changes and bottle
,necks such as shortage of materials mix and.inventory turnover
.V Accurate assessment of manufacturing lead times.and procurement lead times
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.2 MASS AND FLOW PRODUCTION: A system designed to produce several standard
.products in mass quantities This system has capability to produce largequantities of products thereby providing the
management with the advantages of economies of.scale
: ,Example automobiles iron and steel parts
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Production planning and control in continuousProduction( )mass and flow production :
n T he equipment need not be specially designed.for the component to be manufactured
n :Flow Production Plant and equipment andlayout have been primarily designed to
.manufacture a particular product
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Characteristics of Planning and Control for
continuous production:1 Extensive effort is required for detailed planningbefore production status but both scheduling
.and control need not be elaborate usually2 Output is either limited by available capacity or
regulated within given limits to conform to.production targets on periodic sales forecasts
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.3 BATCH PRODUCTION: A production process that is deployed in the
.cases where it is suitable to produce in batches To produce limited number of products with
.varying quantities at periodic intervals : ,Example pharmaceutical companies paint
.manufacturing companies
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PPCin Batch Production:n Batch production is the manufacture of a
number of identical articles either to.meet a specific order
n The decisions regarding tooling and jigs andfixtures are dependent on the quantities
.involved in the production batch
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Characteristics of PPCfor Batch production:
1 Planning and control become more simplified asquantities increase and as manufacture becomes.more regular
2 ,Before issuing manufacturing orders need for raw,materials overloading and under loading of
.particular machines must be anticipated3 Several orders are handled simultaneously in
different work centers scheduling and follow.up becomes a difficult task
4 Dispatching has to be done efficiently to avoid
delays and bottlenecks in the production.process
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.4 JOBBING PRODUCTION: Jobbing production involves production of one or more
.numbers of products whose volume is generally small-The customer and producer work on pre decided
parameters in terms of specifications and cost of.products
: , .Example Tailoring shops Building contractors
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Production planning and control in Job Production:
n , When the order is to be executed only oncethere is either scope for improvement ofproduction techniques by introducing
,intricate method studies special tools or.jigs and fixtures
n , &If the order is to be repeated jigs,fixtures tools as well as speciallydesigned inspecting gauges should becarefully considered to reduce the
.manufacturing cycle time
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Characteristics of PPCfor Job Production:
1 Every job order is of different nature and have.different sequence of operations2 Specific job orders are assigned to different
.work stations as per availability of capacity3 Production schedules drawn depend on the relative
.priority assigned to various job orders4 Scheduling is dependent on assessment of
production times and estimating is based on.judgement
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.5 PROJECT PRODUCTION: Project production can be described as a set of
.activities performed to produce a single productThe product here is immobile and different agencieswith different skill sets are deployed on that
.product to complete it : ,Example Road construction companies construction
companies
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Difference between Production Planning and ProductionControl
.at help line functions in attaining the objectives
. ,ry This function of people in a pure staff capacity is to investigate
Production Planning ProductionControl
.e attainment of the organizational objectives
as being that relationship in which a superior exercises direct supervi