e Lecture Notes for ppc unit 1

DEPARTMENT OF MECHANICAL ENGINEERING

Production Planning and Control

2013-2014

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DEPARTMENT OF MECHANICAL ENGINEERING2013-2014

Unit-1

Chapter -1

1. Objectives , benefits of planning and control and Functions of production control

2. Types of production Job-batch and continuous

Chapter -2

3. Product development and design

i. Marketing aspect

ii. Functional aspects

iii. Operational aspect

iv. Durability and dependability aspect

v. Aesthetic aspect

vi. Profit consideration

vii. Standardization,

viii. Simplification and specialization

Chapter - 3

4. Break even analysis

Chapter - 4

5. New design - Economics

List of possible questions –

AAMEC, KOVILVENNI. PRODUCTION PLANNING AND CONTROL E-LECTURE NOTES

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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.

3. Explain different types of production systems. Differentiate between them.

4. Explain the functional and operational aspects of product design.

5. Explain in detail the production aspects of product design.

Chapter – 1 Objectives, benefits of planning and control and Functions of production control


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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.”

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”

Objectives of PPC

Production Planning and Control aims at the following purposes

1. Continuous Flow of Production: It tries to achieve a smooth and

continuous production by eliminating successfully all sorts of

bottlenecks in the process of production through well-planned routing

and scheduling requirements relating to production work.

2. Planned Requirements of Resources: It seeks to ensure the

availability of all the inputs i.e. materials, machines, tools, equipment

and manpower in the required quantity, of the required quality and at

the required time so that desired targets of production may be

achieved.

3. Co-ordinated work Schedules: The production activities planned and

carried out in a manufacturing organizations as per the master

schedule. The production planning and control tries to ensure that the

schedules to be issued to the various departments/ units/supervisors

are in coordination with the master schedule.

4. Optimum Inventory: It aims at minimum investment in inventories

consistent with continuous flow of production.

5. Increased Productivity: It aims at increased productivity by increasing

efficiency and by being economical. This is achieved by optimising

the use of productive resources and eliminating wastage and spoilage.

6. Customer Satisfaction: It also aims at satisfying customers

requirements by producing the items as per the specifications or

desires of the customers. It seeks to ensure delivery of products on


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time by co-ordinating the production operations with customers

orders.

7. Production and Employment Stabilization: Production planning and

control aims at ensuring production and employment levels that are

relatively stable and consistent with the quantity of sales.

8. Evaluation of Performance: The process of production planning and

control is expected to keep a constant check on operations by judging

the performance of various individuals and workshops and taking

suitable corrective measures if there is any deviation between planned

and actual operations.

Importance of Production Planning and Control

The principal advantages of production planning and control are summarized below

Better Service to Customers:

i. Production planning and control, through proper scheduling and expediting of work, helps

in providing better services to customers in terms of better quality of goods.

ii. Delivery in time and proper quality, both help in winning the confidence of customers,

improving relations with customers and promoting profitable repeat orders.

Fewer Rush Orders:

In an organisation, where there is effective system of production planning and control,

production operations move smoothly as per original planning and matching with the promised

delivery dates.

Better Control of Inventory:

i. A sound system of production planning and control helps in maintaining inventory at proper

levels and, thereby, minimising investment in inventory.

ii. It requires lower inventory of work-in-progress and less finished stock to give efficient

service to customers.

More Effective Use of Equipment:


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It provides information to the management on regular basis pertaining to the present position of all

orders in process, equipment and personnel requirements for next few weeks.

Reduced Idle Time:

Production planning and control helps in reducing idle time i.e. loss of time by workers waiting for

materials and other facilities; because it ensures that materials and other facilities are available to

the workers in time as per the production schedule.

Improved Plant Morale:

It ensures even flow of work and avoids rush orders. It avoids ‘speeding up’ of workers and

maintains healthy working conditions in the plant. Thus, there is improved plant morale as a by-

product.

Good Public Image:

i. A proper system of production planning and control is helpful in keeping systematised

operations to meet its orders in time to the satisfaction of its customers.

ii. Customers satisfaction leads to increased sales, increased profits, industrial harmony and,

ultimately, good public image of the enterprise.

Functions of Production Planning and Control –

A.) Planning Resources 4 M’s


Feedback

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1.

Materials functions -

a.) Includes the specification of materials ( quality and quantity), delivery date,

standardisation procurement and make or by decisions.

b.) It ensures uninterrupted production.

2. Machine –

a.) Related with detailed analysis of the production facilities, equipment downtime,

maintenance policy procedure and schedules.

b.) It includes the analysis of facilities and making their availability with minimum

downtime because of break downs.


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3. Methods –

a.) It is concerned with the analysis of alternatives and selection the best method based on

their constraints.

b.) Developing the specifications for the process with sequence of operation.

4. Measurement –

a.) It deals with the accuracy of the product to be manufactured in the shop floor.

b.) It concerned with the type of sampling involved in the process.

B.) Process planning –

a.) It includes fixation of path of travel giving due consideration to layout and deciding the

setup time and process time for each operation.

C.) Estimating –

a.) 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.

b.) The operation time is done with work measurement techniques.

D.) Loading and scheduling –

It includes the following activities,

a.) Loading the machines as per the capability and capacity.

b.) Determining the start and completion time for each operation in the machine.

c.) Coordinates to meet the delivery schedule.

E.) Dispatching –

The following activities are involved,

a.) To issue required materials from stores.

b.) To record start and finish time of each job on each machine or by each man.


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F.) Expediting

a.) It is logical step after dispatching which is

called “follow up” or “progress”.

b.) To monitor the production rate in the line.

c.) To identify the bottle necks and the

interruptions in the schedule.

G.) Inspection –

a.) This mainly ensures the quality of goods.

b.) It can be required at the time of evaluation process.

c.) It is useful to execute the current and future plans.

H.) Evaluation –

a.) 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.

b.) It depends on the communication, data gathering and analysis.

Types of Production


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Different firms will take different approaches to production. The most common production methods include:


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Job production - functions of PPC

Job production is a onetime production for a specific order. No order no production.

a.) Materials are purchased on receipt of the order

b.) Standard tools are stocked and special tools are either made in house or purchased from

outside.

c.) Schedule is prepared to mark the beginning and finish of each activity.

d.) Based upon the drawings and specifications supervisor decides the work methods in

completion of time.

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.

a.) Functions are more complex.

b.) Detailed route sheets are prepared.

c.) 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. Continuous production is called a continuous process or continuous

flow processes because the materials, either dry bulk or fluids that are being processed are

continuously in motion, undergoing chemical reactions or subject to mechanical or heat treatment

a.) Material function is critical.

b.) No process planning activity.

c.) Scheduling is restricted to final quantity required


http://en.wikipedia.org/wiki/Manufacturing

http://en.wikipedia.org/wiki/Flow_production

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Chapter – 2

Product

development and

design

Production Design process


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Organisation’s are required to design a new products for the following reasons,

1. To satisfy the needs of the customers.

2. The profit margin is on the decline stage.

3. To be competitive in the market.

A.)Stage – I Conception

This stage provides the basis for all subsequent design activities. The following information’s

should be furnished,

1. The performance requirements.

2. Aesthetics requirement.

3. The estimated quantity to be sold.

4. The probable date of the new product enters into the market.

B.)Stage – II Acceptance

1. Design activity of the product design after the feasibility analysis

2. Prototype manufacturing and design calculations are made.

C.)Stage – III Execution


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1. The model should conform to the real time specifications.

2. The cost

of the product

is built at this

stage with the

team of

production

engineers.

3.

Advanced

techniques like

RPT,

Experimental stress analysis for modelling and testing.

D.)Stage – IV Translation

1. The manufacturing feasibility is tested on this stage.

2. The manufacturing drawings are prepared.

E.)Stage – Pre-Production

1. This stage will ensure the quality, reliability of the product as per the specifications before

the actual production starts.

2. Pre-Production stage will check,

a.) Drawings b.) Tools C.) Productions techniques and etc,.

Product analysis


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1. Marketing aspects –

The marketing analysis for the proposed product seeks to give

answer for the following questions,

Status of the product in the market. (Product is already existing or a new product)

a.) The expecting demand and factors influencing the demand.

b.) The level of the competition in the market.

c.) Offers given by the competitors.

d.) Distribution systems to the market.

e.) Advertisement promotions.

2. Product Characteristics –

a.) Functional aspects –

i. Various functions performed by the product.

ii. The product should give in single or multiple functions.

iii. If the product is in multiple functions the estimation of cost for that.

Example - Tape recorder


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1) Additional facilities like

clock, light.

2) Whether it’s single or twin

cassette recorder.

3) Whether it is portable or stationary.

4) It is manufactured with safety measures.

b.) Operational aspects –

1) The product is used at different operational conditions by the customers.

2) The product is not only expected to perform its functions satisfactorily but it should be easy

to handle at the customers end.

Example - Tape recorder

c.) Reliability -

Durability and dependability the two factors define the quality and reliability of

the product.

Durability refers to the active length


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Uniform Resource Locator -

http://www.nwlean.net ( Lean Manufacturing Terms)

http://www.conceptdraw.com ( Production related diagrams)

http://www.gembutsu.com (Glossary)

http://www.welingkaronline.org (Manufacturing methods)

http://en.wikipedia.org ( Manufacturing methods)


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