Production planning & control
• Production: sequence of operations that transforms materials from a
given form to a desired form.
• Efficiency in Production: By manufacturing
• Required quantity
• Of required quality
• At required time
• By best & cheapest method
• To achieve the above objective Production Planning & Control is
employed as a Management Tool.
• 3 Main Stages in Production Planning & Control (PPC)
• Planning:
• Choice from among best alternatives
• Utilizing resources available
• Achieving objectives in most efficient & economic manner
• Operations:
• Performing according to the details set out in the production plan
• Control:
• Monitoring of performance through feedback
• Responsible for subsequent adjustments, modification and redefining of plans and
targets
PPC- Management Tool defined as:
The planning, direction and
coordination of the firm’s
material and physical
facilities towards the
attainment of predetermined
production objectives in the
most economical manner.
Functions of PPC:
• Materials:
• Availability of raw materials, spare parts & components in correct quantities and
specifications at the right time.
• Methods :
• Deciding best sequence of operations
• Building up subassemblies and major assemblies
• Machines & Equipments:
• Selection of machines & equipments
• Maintenance policy, replacement policy
• Procedures, tooling etc
Functions of PPC:
• Routing:
• Prescribes the flow of work in the plant
• Relates to considerations of layout
• Temporary storage locations for raw materials, components & processed parts
• Material handling system
• Estimating:
• Processing times (set up+ operation time per piece) required for in-house
manufacturing
• Standard time (machine + labour time) as performance standards.
Functions of PPC:
• Loading :
• Machines are loaded according to their capacity & capability.
• Machine loading carried out in conjunction to routing.
• Scheduling
• Determines the efficiency of the plant (utilization of equipment & man power)
• Determines the Starting time & completion time for each & every operation
and for each & every part to be manufactured.
• Helps to achieve pre determined deliver schedules.
Functions of PPC:
• Dispatching :
• Execution of planning functions
• Release of production orders according to schedule
• Adhering to sequence indicated in route sheets, machine loading schedules
• Authorization provided for release of materials and tools to operators
• Expediting:
• Follows the function of dispatching
• Follow-up or keeping track of progress made in completing the production as per
schedule.
• keeps close liaison with work centers to provide feedback to production manager
regarding any prompt review of targets & schedules.
Functions of PPC:
• Inspection:
• Checking quality in production
• Evaluating efficiency of the processes, methods & workers to achieve desired
level of quality
• Evaluating / Controlling:
• Assessing performance effectiveness
Aim of Production Planning:
• 4M’s – resources of Men, Machinery, Materials & Money analyzed
to select most appropriate Materials, Methods and facilities for
accomplishing the work.
• Tasks such as Routing, Estimating and Scheduling follows.
Choice of Production Planning depends on:
• Volume of Production:
• Determines the amount and intensity of production planning
• Extensive planning required for high volume operations
• To achieve cost-reduction
• In case of Custom Order planning is limited
• Purchase of raw materials
• Components
• Determination of work centers
• Nature of Production Processes:
• In case of Job Shop, planning is informal
• Development of work methods left to individual workman (highly skilled)
• In case of high volume production enormous amount of effort put in
designing product & manufacturing processes.
• Product designers, equipment designers, process designers , method designers
• Nature of Operations:
• Detailed production planning required for repetitive operations.
• Variants in Manufacturing Approach:
• Manufacturing to order (may /may not be repeated at regular intervals)
• Manufacturing for stock & sell (under repetitive batch/ mass production.)
• Manufacturing for stock & sell (under continuous process manufacturing)
Production Control: Importance
• Provides for the production of parts, assemblies and products of
required quality and quantity at the required time.
• Co-ordinate, monitor & feedback to manufacturing management
• Provide for optimum utilization of all resources
• Achieve low cost production & reliable customer service.
Elements of Production Control:
Control of Control of
Control of
Manufacturing Material
Planning
Capacity Handling
Control of Control of Control of Due
Materials Activities Date
Control of Control of Control of
Tooling Quantity Information
PPC and Decision Making:
Question Answer
What to produce Production Planning & development including Product
Design
How to produce Process Planning, Material Planning, Tool Planning etc
Where to Produce Facilities Planning, Capacity Planning, and Sub-
Contracting Planning
When to Produce Production Scheduling, Machine Loading
Who will Produce Man Power Planning
How much to produce Planning for quantity, Economic Batch Size etc
Phases In PPC Functions
Planning Phase
(Pre Planning & Active
Planning
Action Phase
Control Phase
PLANNING Phase : Pre Planning:
Product Demand Resources
Planning Forecasting Planning
Location &
Facilities
Layout
Planning
Planning
PLANNING Phase: Active Planning
Planning for Routing
Product Mix
Quantity & Scheduling
Material
Process
Planning, Tool
Planning
Planning etc
ACTION PHASE:
Progressing
Dispatching
Execution
Phase
CONTROL Phase :
Status
Reporting
Cost Material
Control Control
Labour
Tool
Output
Control Control
Quality Inventory
Control Control
Levels of Production Planning:
Strategic Tactical Operational
Planning Planning Planning
Main functions of PPC:
Production Production
Planning Control
Estimating
Dispatching
Routing Expediting
Scheduling Inspection
Evaluating &
Loading Corrective
action
