Production Planning and control – ME 1009 Unit 1 Introduction

Syllabus & Lesson Plan Chapter.No.Chapter Lecture hrs Lecture hrs as per syllabus Lecture hrs Planned 1 & 1.1 Objectives and benefits of planning and control 9 1 Functions of production control and Types of Production 1 2Product development and Design2 3 Break even analysis2 4 Economics of new design2 Unit – 1 Introduction PPC

Chapter - 1 In the words of Henry Fayol – “Production control refers to ensuring that all which occurs is in accordance with the rules established and instructions issued.” Basic Definitions In the words of Kimball – “Production planning refers to planning of industrial operations involves four considerations, namely, what work shall be done, how the work shall be done and lastly, when the work shall be done.” Production planning and control refers to “direction and coordination of firms resources towards attaining the prefixed goals”

Need for PPC 1.Effective utilizations of firms and resources 2.To achieve the production objectives w.r.t quality, quantity, cost and timelines of delivery 3.To obtain the uninterrupted production flow in order to meet customers varied demand w.r.t committed delivery schedule. 4.To help company to supply a good quality products to the customer on the continuous basis at competitive rates

Objectives of PPC 1.Systematic planning of production activities to achieve the highest efficiency in production of goods. 2.To organize the production facilities like machines, men, etc. 3.Optimum scheduling of resources 4.Coordinate with other departments relative to production to achieve regular balanced and uninterrupted production flow. 5.To confirm to delivery commitments 6.Materials planning and control 7.To be able to make adjustment due to changes in demand and rush orders.

Functions of PPC 4 m’s Process Planning/ Routing SchedulingEstimatingDispatchingInspectingExpeditingEvaluation Feedback 1.Materials 2.Machine 3.Methods 4.Measurements

1.Materials - 1)Includes the specification of materials ( quality and quantity), delivery date, standardization procurement and make or by decisions. 2)It ensures uninterrupted production. 2.Machine – 1)Related with detailed analysis of the production facilities, equipment downtime, maintenance policy procedure and schedules. 2)It includes the analysis of facilities and making their availability with minimum downtime because of break downs. 3.Methods – 1) It is concerned with the analysis of alternatives and selection the best method based on their constraints. 2)Developing the specifications for the process with sequence of operation. 4.Measurement – 1)It deals with the accuracy of the product to be manufactured in the shop floor. 2)It concerned with the type of sampling involved in the process. Planning Resources 4 M’s

5.Process planning / Routing It includes fixation of path of travel giving due consideration to layout and deciding the setup time and process time for each operation. 6.Estimating – 1)Once the overall method and sequence of operations is fixed and process sheet is available. Hence with use of the process sheet the operations times are estimated. 2)The operation time is done with work measurement techniques. 7.Loading and scheduling – It includes the following activities, 1)Loading the machines as per the capability and capacity. 2)Determining the start and completion time for each operation in the machine. 3)Coordinates to meet the delivery schedule.

8.Dispatching – The following activities are involved, 1)To issue required materials from stores. 2)To record start and finish time of each job on each machine or by each man. 9.Expediting 1)It is logical step after dispatching which is called “follow up” or “progress”. 2)To monitor the production rate in the line. 3)To identify the bottle necks and the interruptions in the schedule. 10.Inspection – 1)This mainly ensures the quality of goods. 2)It can be required at the time of evaluation process. 3)It is useful to execute the current and future plans.

11.Evaluation – 1)It helps to identify the weak spots and the corrective action w.r.t the pre-planning and planning will be effected by the feedback. 2)It depends on the communication, data gathering and analysis. Key words to remember 4 m’s Process Planning/ Routing SchedulingEstimatingDispatchingInspectingExpeditingEvaluation Feedback

University questions from chapter 1 1.What do you understand by production planning and control? Discuss its main elements. 2. Enumerates the activities involved in the production planning and control function under the Convenient points. 1. Define production planning and control. 2. List the objectives of PPC. 3. What are the phases of production planning and control? 4. List various functions of PPC.

Types of Production Different firms will take different approaches to production. The most common production methods are, 1. Job production - functions of PPC “Job production is a onetime production for a specific order. No order no production”. 1)Materials are purchased on receipt of the order 2)Standard tools are stocked and special tools are either made in house or purchased from outside. 3)Schedule is prepared to mark the beginning and finish of each activity. 4)Based upon the drawings and specifications supervisor decides the work methods in completion of time. 1.Job production 2.Batch production 3.Continuous or flow production Chapter – 1.1

Batch production – functions of PPC “Batch production is a mass production method where the process waits until a product is finished in a workstation before it was transfer to the next process”. 1)Functions are more complex. 2)Detailed route sheets are prepared. 3)Loading and scheduling are to be worked out with greater details. Continuous production – functions of PPC “Continuous production is a flow production method used to manufacture, produce, or process materials without interruption”. 1)Material function is critical. 2)No process planning activity. 3)Scheduling is restricted to final quantity required

Key words to remember 1.What is production system? 2. List the types of production system 3.Explain different types of production systems. Differentiate between them. University questions from chapter 1.1

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