Gives introduction about PPC

1. PRODUCTION
PLANNING AND
CONTROL

2. What is Production Planning
And Control (PPC)
PRODUCTION: that transformation of raw
materials to finished goods.
PLANNING: looks ahead, anticipates
possible difficulties and decides in advance
as to how the production, best, be carried
out.
CONTROL: phase makes sure that the
programmed production is constantly
maintained.

3. PRODUCTION PLANNING
 Given a specific process planning, process
technologies and production conditions.
 predetermine varieties, quantities, quality,
and scheduled of products to be produced
according to market demand of products.

4. PRODUCTION PLANNING & CONTROL
THERE ARE THREE STAGES IN PPC
PLANNING : The choice from several alternatives of
the best utilizing the available resources to achieve
the desired objective .
OPERATIONS: Performance in accoRDANCE WITH
DETAILS SET OUT IN PRODUCTION PLAN.
CONTROL: The monitoring of performance through a
feed back by comparing the results achieved with
planned targets so that performance can be
improved.

5. Objective of PPC
 To deliver goods in required quantities to
customers in required delivery schedule
 To ensure maximum utilization of all resources
 To ensure production quality products
 To minimize the product throughput time
 To maintain optimum level inventory
 To maintain flexibility in manufacturing operations
 Coordinate between labour and machines and
various supporting departments

6. Functions of PPC
 Routing
 Estimating
 Scheduling
 Loading
 Dispatching
 Expediting
 Evaluating
 Inventory Control

8. Pre Planning, Planning & Control
Pre Planning
Phase before
Actual Planning
It Involves,
Data collection,
Product Design &
development
Forecasting of
4M’s
Sales and Market
Research
Etc.,
Planning
Production planning is
an activity that is
performed before start
of actual production
process.
It involves Determining
The schedule of
production
Sequence of operations,
Economic batch
quantities,
Dispatching priorities
Control
Production control is
mainly involved in
implementing production
schedules and is the
corollary to short term
planning or scheduling
It includes,
Initiation of
production,
Dispatching items,
Progressing,
Feed back

9. Types of Planning
 Strategic Planning(Long range): For future needs
Ex: Technology forecasting and choice of
appropriate technology for the long range time
horizon.
 Tactical Planning(Intermediate Range): These
plans focus on aggregate products rather than
individual products.
 Operational Planning(Short Range): It is concern
with utilization of existing facilities rather than
creation of new facilities.

10. Elements of Production Control
Plan PROCESS
Data
Collection
Interpretation
Error
Corrective
Action
O/P
I/P

11. Types of Production Systems
Production systems are usually classified on
the basis of the following:
 Type of product,
 Type of production line,
 Rate of production,
 Equipment used etc.

12. Types of Production Systems
The Broad classification is
 Job Order production
 Batch production
 Mass production

13. Job Production
 products are made to satisfy a specific order
√ only once
√ or at irregular time intervals as and when
new order arrives
√ or at regular time intervals to satisfy a
continuous demand

14. Important characteristics
φGeneral Purpose Equipment is used
φFlexible Planning and control system to deal frequent
changes.
φSkilled workers are required
φNo definite data is available
φHigh in-process inventory
φHigh Product cost
φMachines are grouped based on function
φFlexible system either for production or for material
handling

15. Batch Production
 manufacturing of a number of identical
articles either to meet a specific order or to
meet a continuous demand
 Batch can be manufactured either-
✓ only once
✓ or repeatedly at irregular time intervals as
and when demand arise
✓ or repeatedly at regular time intervals to
satisfy a continuous demand

16. Important characteristics
Economical production
Machines are grouped based on function
Semi automatic, special purpose automatic
machines can be used
Skilled workers are required
High in-process inventory
Semi automatic material handling systems are
used
production planning and control is difficult due to
the odd size and non repetitive nature of order.

17. Mass Production
 same type of product is manufactured to
meet the continuous Demand
 demand of the product is very high
 same demand sustains for sufficiently long
time.

18. Important characteristics
Product type layout is used
Standard methods and machines are used
Equipment are semi automatic or
automatic in nature
 Automatic Material handling systems
Semi skilled workers are sufficient
planning and control of the system is much
easier
Cost of production is low
In process inventories are low

19. Benefits of PPC
 PPC coordinates all the phases of production/
Operating system
 An efficient plan results in higher quality ,better
utilization of resources, reduced inventories, better
customer services.
 An efficient plan enable the firm to improve its sales
turnover , market share and profitability.

20. Limitations of PPC
 PPC function is based on certain assumptions or
forecasts of customer’s demand, Plant capacity,
availability of materials etc.,
 Employee may resist change in production levels set as
per production plans.
 This process is time consuming when we need to carry
out routing and scheduling function for large products.
 This function become difficult when environmental
factors changes rapidly.

21. Internal organization of PPC department
Production Planning
Orders booking &
production budget
Materials Records
Methods
Machines
Tool &Jig Design
Operation Layout &
Routing
Time estimating
scheduling
Production Control
Dispatching
Expediting
Motion & Time
Study
Transportation
Inventory control
Stores
Management
Quantity control
Purchasing
Receiving
Simplification
PPC