PRODUCTION PLANING AND CONTROL,

1. MGM’S COLLEGE OF ENGINERRING AND
TECHNOLOGY
Department of Mechanical Engineering
Presentation Report on
“Recent Trends in Advanced Manufacturing system”
Presented by:
Akshay Ghanwat
Guided by
Prof.kumbhar sir

2. INDEX
Sr.
no
CONTENT
1) INTRODUCTION
2) ADVANCED MANUFACTURING SYSTEM
3) TYPES AND EXPLANATION
4) ADVANTAGES AND DISADVANTAGES
5) CONCLUSION

3. INTRODUCTION:
What is manufacturing?
A-The process of converting raw materials into finished products
B-Chemical or Physical transformation of the materials, substances or
components into some new products
C-Manufacturing is the use of machines, tools and labor to make things
for use or sale
ManufacturingSystem:
In order to consider manufacturing, as a system; we need to look
beyond the conversion of raw materials and processes which lead to
finished products. The understanding of the manufacturing system as a
whole helps in identifying, which process parameters and functions of
the organizations are important; this helps to make decisions about the
economical ways of producing the end products. There are several
factors which are usually considered in taking a final and relevant
decision about the best way of producing the desired end product. A
manufacturing system can be considered as a simple input-output
system at the first stage.

4. ADVANCED MANUFACTURING SYSTEM:
A number of organizations also
included business or management methodologies in their definition of
advanced manufacturing. For example, one organization defines
“advanced manufacturing as the insertion of new technology, improved
processes, and management methods to improve the manufacturing of
products.” (National Defense University, 2002, as reported in PCAST)
Another organization lists advanced manufacturing as
“encompassing lean production techniques, enhanced supply chain
integration, and technology assimilation.”[4]
In fact, the Wikipedia
definition of “advanced manufacturing” is “advanced planning and
scheduling” described as “a manufacturing management process by
which raw materials and production capacity are optimally allocated to
meet demand.” Overall, the following business or management
methodologies were listed as being a part of advanced manufacturing:
 Quality controls (US Department of Labor)
 Lean production technologies
 Supply chain integration
 Advanced Planning and Scheduling (Wikipedia, online, accessed June
2010)
Traditional vs. Advanced Manufacturers:
Traditional Manufacturing is defined[5]
as the act of converting raw
materials into finished products by using manual or mechanized
transformational techniques. The purpose of such activities is to add

5. value to achieve targeted objectives, which do not preclude society’s
overall interests. In one report, the distinction between traditional
sectors of manufacturing (listed as auto, steel) and others (listed
as aerospace, medical device, pharmaceutical) is the basis for a
definition of advanced manufacturing, with the characteristics of the
two differing in terms of volume and scale economies, labor and skill
content, and the depth and diversity of the network surrounding the
industry.

6. TYPES:
1)JUST IN TIME:
(IT IS NOT BEFORE,ITIS NOT AFTER ,IT IS ON TIME)
Just in time is a system that has universal existence.Itcan be applied to
any field of operations.It’s imply right things at the right time. Just-in-time
(JIT) manufacturing, also known as just-in-time productionor the Toyota
productionsystem (TPS), is a methodologyaimed primarily at reducing
flow times within production as well as response times from suppliers and
to customers.Following its origin and developmentin Japan, largely in the
1960s and 1970s and particularly at Toyota.
Alternative terms for JIT manufacturing have beenused. Motorola's choice
was short-cycle manufacturing (SCM). IBM's was continuous-flow
manufacturing (CFM), and demand-flowmanufacturing (DFM), a term
handed down from consultant John Constanza at his Institute of
Technologyin Colorado. Still another alternative was mentioned by
Goddard,who said that "Toyota Production System is often mistakenly
referred to as the 'Kanban System,'" and pointed out that kanban is but one
element of TPS, as well as JIT production
But the wide use of the term JIT manufacturingthroughout the 1980s faded
fast in the 1990s,as the new term lean manufacturingbecame
established as "a more recent name for JIT. As just one testament to the
commonality of the two terms, Toyota production system (TPS) has been
and is widely used as a synonym for both JIT and lean manufacturing.
ADVANTAGES:
1)It reduces the waste ,obsolete and damaged stocks
2)It improves the cash flow as the money is not tied up in the stocks
3)the supplierbase is reduced is reduced significantly
4)controls demand for suppliers in production
5)more factory space is made available for production

7. DISADVANTAGES:
1)a lot of faith is placed in the suppliers
2)it increases the ordering and administrative costs
3)sometimesit is hard to handle the sharp increase of demands
2)COMPUTER INTEGRATED PROCESS PLANNING(CIPP)
It is the process in which the entire system is computerized.The features
Are as follows:
 All the planning processare computerized
 All the functioning of the companycan be seenone window
 The modificationcan be done from any remote corner of the world
 The labour force is required for planning is reduced
 The entired lifecycle of the product can be monitored
Computer-integratedmanufacturing is
the manufacturing approach of using computers to control the entire
productionprocess.[1][2]
This integration allows individual processes to
exchange information with each other and initiate actions. Although
manufacturing can be faster and less error-prone by the integration of
computers,the main advantage is the ability to create automated
manufacturing processes.Typically CIM relies on closed-loop control
processes,based on real-time input from sensors.It is also known
as flexibledesignand manufacturing
Process planning is concerned with determining the sequence of individual
manufacturing operations needed to produce a given part or product. The
resulting operation sequence is documented ona form typically referred to

8. as a route sheet (also called as processsheet/method sheet)containing a
listing of the productionoperations and associated machine tools for a work
part or assembly.Process planning in manufacturing also refers to the
planning of use of blanks, spare parts, packaging material, user instructions
(manuals) etc.
The term "Computer-Aided ProductionPlanning" is used in different
contexts on differentparts of the productionprocess;to some extent CAPP
overlaps with the term "PIC" (Productionand Inventory Control).
Process planning translates designinformation into the processsteps and
instructions to efficientlyand effectivelymanufacture products.As the
designprocess is supported by many computer-aidedtools,computer-
aided processplanning (CAPP) has evolved to simplify and improve
process planning and achieve more effective use of manufacturing
resources.[2]
processplanning is of two types as- 1. generative type
computeraided process planning.2. variant type process planning
3)ENTERPRISE RESOURCE PLANNING(ERP):
Enterprise resource planning is a business management software having
integrated applications that a company uses to collect, store and manage
and interpret the data for many business activities like product planning,
manufacturing, marketing and sales, inventory manufacturing ,shipping and
payment.
considered an enterprise application as it is designed to be used by larger
businesses and often requires dedicated teams to customize and analyze
the data and to handle upgrades and deployment.In contrast, Small

9. business ERP applications are lightweight business management software
solutions, often customized forthe business industry you work in.
.
ERP (Enterprise Resource Planning) systems typically include the
following characteristics:
 An integrated system that operates in (or near) real time without relying
on periodic updates
 A commondatabase that supports all applications
 A consistentlook and feelacross modules
 Installation of the system with elaborate application/data integration by
the Information Technology(IT) department, provided the
implementation is not done in small step
Advantages of ERP System
 Integration of the various departments ensures communication,
productivity and efficiency.
 Adopting ERP software eradicates the problem of coordinating changes
between many systems.
 ERP software provides a top-down view of an organization, so information
is available to make decisions at anytime, anywhere.
Disadvantages of ERP System
 Adopting ERP systems can be expensive.
 The lack of boundaries created by ERP software in a company can cause
problems of who takes the blame, lines of responsibility and employee
morale.

10. 3)MRP:
The inputs to the MRP system are:
1. a master productionschedule(MPS)
2. an inventory file and bill of material(BOM)
Using these three information source the MRP processing logic provide
three kinds information, Materialrequirements planning (MRP)is
a productionplanning, scheduling, and inventory control system used
to manage manufacturing processes.Most MRP systems aresoftware-
based, while it is possible to conductMRP by hand as well.
An MRP system is intended to simultaneously meet three objectives:
 Ensure materials are available for production and products are available
for delivery to customers.
 Maintain the lowest possible material and productlevels in store
 Plan manufacturing activities, delivery schedules
and purchasing activities
MRP Planning Parameters:
MRP parameters are required for MRP run in terms of considering the
requirements (PIR) in planning horizon, scheduling parameters and about the usage
of BOM and routing data.
1. Processing Key
1. Net change (NETCH): In this run, the system considers those materials in
the planning run from their last MRP run which have undergone some
changes pertaining to receipts and issues or any stockchanges.

11. 2. Net Change in Planning Horizon (NETPL): In this run, the system considers
those materials in the planning run from their last MRP run which have
undergone some changes pertaining to receipts and issues or any stock
changes. It considers the requirements in a pre-defined planning horizon,
unlike NETCH key which considers the total futuristic requirements.
3. Regenerative Planning (NEUPL): It plans all the materials for the MRP Run
irrespective of the changes they undergo. This plan is not so widely used. It
takes a long time to obtain the final result.
2. Planning Mode
1. Adapt planning data: Itonly processes thechanged data.
2. Re explodes BOMand Routing: Read BOMand routing data again for the
existing orders.
3. Delete and recreate planning data: Itcompletely deletes the planning data
(all receipts) and creates again.
3. Scheduling
1. Basic Scheduling: MRP calculates only basic dates for the orders and in
houseproduction time for the material master is used.
2. Lead Time Scheduling: The production dates are determined by the lead
time scheduling for planned orders. Theroutings are read to schedule and
calculate the capacity requirements on work centers.

12. CONCLUSION:
"Advanced manufacturing entity makes extensive use of computer ,high
precision and information technologies integrated with a high
performance workforce in a production system capable of furnishing a
heterogeneous mix of products in small or large volumes with both the
efficiency of mass production and the flexibility of custom
manufacturing in order to respond quickly to customer demands”