Production Planning and Control by Aijaz Aryan

1. PPC
Production Planning and
Control
Aijaz Ahmed Rather
I.K Gujral P.T University

2. Production Planning
Production planning and control may be defined as
the direction and coordination of the firm’s material
and physical facilities towards the attainment of pre-
specified production goals in the most efficient
available way .
It is the organization and planning of the
manufacturing process.

3. Objectives of PPC
Continuous Flow of Production
Planned Requirements of Resources
Coordinated work Schedules
Optimum Inventory
Increased Productivity
Customer Satisfaction
Production and Employment Stabilization
Evaluation of Performance

4. Factors determining PPC in a Manufacturing
System
Interdependence of various operations involved in a
transformation process.
No. of operations ,parts, sub assemblies required to
get a final product.
Nature and magnitude of variation in capacity of
machines and equipments.
Size of order and production run
Nature of Manufacturing System.

5. Production Planning
Production Planning= Production + Planning
Production= Activities involved in Transformation
Process.
Planning=Coordination ,Formulation and determination
of these activities.
PP=Deals with resources required for manufacturing
and allocation of resources to produce output at least
cost.

6. Levels of Production Planning
 Factory Planning: Planning about building ,Machines and
Equipments required .
 Process Planning: Locating the operations and their sequence.
 Operation Planning: Planning the methods to perform
operations

7. Planning and Manufacturing Systems
PP depends upon nature of manufacturing system.
For intermittent systems ,PP is complicated .
For continuous systems, PP is simple.

8. Objectives of PP
Systematic co- ordination and regulation of various
activities
Proper balance of the activities
Determination of input requirements for desired
output.
Anticipation of business changes

9. Programming

10. Routing
Determination of path or route over which
each piece is to travel in being transformed
from raw material into finished products.

11. Routing
 It defines the exact process by which a product is to be manufactured
or a service is to be delivered. Thus the purpose of routing is to spell the
most efficient and economical way to perform a function.
 Routing directions are prepared keeping in mind the number of
employees, types of equipment available; their capacity and run time.

12. Rote sheet
 It is the map or the blueprint of the manufacturing
process in a production unit. It provides the exact
location of the various processes of the unit.
 A route sheet determines the sequence or order of
arrangement of various departments in a facility.
 Thus, a route sheet is a document which has
information and data inputs and a step wise listing of
all the processes or transactions performed.
 It also contains details such as date and time,
remarks, log in/out, point of contact etc.

13. A typical route sheet contains the following
information
 Identification and sequence of work arrangement.

Symbol or sign of a component of the product

Appraisal or assessment of the process or method which
is being followed.

Computing the number of units to be produced.

Machines and tools used in the operation, their run time,
efficiency and capacity.

Evaluation of the entire production process

14. Route sheet of pencil manufacturing
unit
Raw materials reqd: graphite, clay, wax, cedar,
ferrule, pumice, rubber, metal, prongs, dyes,
pigments, gum.
Symbols used in the manufacturing process:

O = Operation
I = Inspection
T = Transportation
S = Storage
D = Delays

15. Route Sheet

16. Scheduling
Allocation of resources over time to accomplish
specific tasks.
It means working out of time that should be required
to perform each operation and also the time
necessary to perform the entire series as routed,
 Making allowances for all factors concerned.

17. Contd.
 Mainly concerns with time element and priorities of
a job.
 The schedule will to produce 300 units of articles
during week number 1,200 units during week 2and
so on.

18. Classification of Schedules.
Operation Schedule
Master Schedule

19. Operation Schedule
 The main aim is to schedule that amount of work
which can easily be handled by plant and equipment
without interference.
 It takes into account following factors.
 Time required
 Material, Machines and Labor required.

20. Master Schedule
It is a list showing how many of each item to make in
each period of time.
 weekly or monthly break-down of the production
requirement for each product for a definite time
period.
A master schedule is followed by operator schedule.
Nature of manufacturing schedule depends upon
decision of make or buy.

21. Scheduling devices
Gantt Chart
PERT/CPM
Run out approach

22. Loading
Study of load and capacity at workplaces.
No. of machines available and their characteristics

23. Objectives of lading
To plan new work orders
To balance work load
To maintain delivery processes.

24. Loading devices
 Load step by step
 Machine Loading

25. Contd.
 Machine Loading: weekly and periodic load is
determined for each machine and then recorded on
machine load chart.
 Machine load chart for all the machines in
production dept. shows the future spare capacity of
machines.

26. PRODUCTION CONTROL
 Methods and procedures employed in
handling materials, parts, assemblies, and
subassemblies, from their raw or initial
stage to the finished product stage in an
organized and efficient manner. It also
includes activities such as planning,
scheduling, routing, dispatching, storage,
etc.

27. Programming
Regulates the supply of finished product in desired
amount at due date.
Involves three types of decisions:
Nature of product to be manufactured.
Amount of quantities to be produced.
When to produce.

28. Objectives of production programming
Reliable delivery to the customer.
Efficient use of capital.
Even loading of the plant.

29. ORDERING
Breaking down the requirements for products to be
completed at specific times into orders for materials
and processed parts and making them available
when needed.
Work orders :order authorizing production is
known as work order.
Work orders are prepared on the basis of quantity
required and order quantity.

30. Dispatching
 it is setting production activities in motion through
the release of order & instructions in accordance
with previous plans.
Decision of assigning various jobs to different
machines is known as dispatching.

31. Follow up
 Checking production activities systematically to
remove bottlenecks in flow of work and ensuring that
production activities are carried acc to plans.

32. Contd.
 spots deviations
Reveals defects in routing & scheduling.
Correct misunderstandings of orders & instructions.

33. Inventory Control

34. PP PC
 Formulation of
production strategies &
targets.
 Determines the operations
required to manufacture
some product.
 Actual implementation &
execution of planned
activities.
 Regulates & supervises
these operations.
Difference b/w production planning & control

35. PLANNING
OPERATI
ONS CONTROL
MODIFICATIONS
INFORMATION

36. Thank You