introduction to production planning and control by Saheb Shaikh

1. PRODUCTION
PLANNING AND
CONTROL (PPC)
By :-
• Saheb Shaikh
• Tushar Powar
• Sarvesh Patil
• Hrushikesh

2. Topics to be covered
• Defination of PPC
• History
• Need of PPC
• Objectives
• Characteristics
• PPC process

3. What is PPC ?
• Production Planning can be referred to as a technique of forecasting
every step in the long process of production, taking them at right
time and in the right degree and trying to complete operations at
the maximum efficiency.
• Production control is the process that keeps a watchful eye on the
production flow, size of resources along with any deviation from
the planned action. It also includes arrangement for the prompt
remedy or adjustment in case of any deviation so that the
production may run according to the original or revised schedule.

4. History
• PPC concept developed since late 19th Century
• Factories were simple and relatively small
• Small number of products with large batches
• Work for each man and each machine used to be chalked out
• Even as factories grew , they were just bigger , not more complex .
• Main Industry – Textiles , Railways

5. Need 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. Objectives

7. Characteristics
• Inputs like materials, men and machines are efficiently used
• Factors of production are integrated to use them
economically
• Division of work is undertaken carefully so that every
available element is properly utilized
• Work is regulated from the first stage of procuring raw
materials to the stage of finished goods
• Questions like what, when and how to be manufactured are
decided

8. PRODUCTION PLANNING involves….
• Preparation of production budget .
• Devising manufacturing methods and sequence of operations.
• Deciding type of machines and equipments .
• Preparation of operation sheets and instruction cards.
• Estimating men, machine and material requirements.
• Undertaking time and motion studies .
• Preparing master schedules.

9. PPC Process

10. • Planning : What is the Task ?
• Routing : Where it needs to be
carried out?
• Scheduling : When it needs to be
carried out ?
• Loading : Who will perform the task
?
Process

11. Planning :-
It is the first element of production planning and control. Planning
means deciding in advance what is to be done in future. An
organizational set up is created to prepare plans and policies. Various
charts, manuals and production budgets are also prepared.
Routing :-
“Routing is the specification of the flow sequence of
operations and processes to be followed in
producing a particular manufacturing lot.”( Alford
& Beaty)

12. Scheduling :-
Scheduling is the determining of time and date when each operation
is to be commenced or completed. The time and date of
manufacturing each component is fixed in such a way that
assembling for final product is not delayed in any way.
The next step is Loading which is execution of the
scheduled plan as per the route chalked out. It
includes the assignment of the work to the operators
at their machines or work places.
Loading :-

13. Dispatching refers to the process of actually
ordering the work to be done. It involves putting the
plan into effect by issuing orders. It is concerned
with starting the process and operation on the basis
of route sheets and schedule charts.
Dispatching :-
Progress may be assessed with the help of routine
reports or communication with operating
departments. The follow up procedure is used for
expediting and checking the progress.
Follow up :-

14. Inspection :-
• Inspection is the process of ensuring
whether the products manufactured are of
requisite quality or not.
• Inspection is undertaken both of products
and inputs. It is carried on at various levels
of production process so that pre-
determined standards of quality are
achieved.
• Inspection ensures the maintenance of
pre-determined quality of products.

15. • Adjusting the route
• Rescheduling of work
• Changing the workloads
• Repairs and Maintenance of
machinery or equipment,
• Control over inventories
• Certain personnel decisions like
training, transfer, demotion etc.
• Alternate methods may be
suggested to handle peak loads.
24
Corrective Measures :-

16. Data Prerequisites of PPC
Data Pertaining to Design :-
The design of the product is most important
which is supplied by the customer. Based on
the design provided, the entire shop floor
plan is decided.
Data pertaining to Equipment’s :-
The equipment’s required for
manufacturing the products mainly
follow a sequence of operations to
be performed on the same. These
also include the tooling and
accessories necessary for holding
the job in the machine.

17. Data pertaining to raw materials :-
The raw material requirements for
products depends mainly upto the
customer requirements and demands,
the type of material to be used ,
specifications like composition
chemical involvement , type of
process etc.
Data pertaining to tooling :-
Type of tooling depends upon
composition of workpieces. It also
incorporates the method of
machining to be carried out that will
give standardized sizes of tools and
cutting accessories required for
production.

18. Data pertaining to performance standard :-
In an industrial engineering process, taken as a whole, there are some
standard methods or procedures to be followed while planning a
process. The production planning techniques are mainly based on the
type of end or final products to be made.This is decided by the type of
drawing or part diagrams sent by the customers.
Data pertaining to operating systems :-
The operating systems considered in an industry mainly
and wholly depend upon type of products to be
manufactured. The final end products decide the type of
operating system applicable. It is usually called as the
plant layout planning. The layout of the plant forms a
major part of operating system.

19. Data pertaining to Labour :-
Management of labour on shop floor along with the
assignment of Jobs and productivity output.Labour
required in Industrial engg is mainly categorized into
• Labour at management level
• Labour at staff level
• Labour at shop floor level

20. • Assumption based
• Rigidity
• Difficult for small firms
• Costly
• Dependence on external factors
• Team work is a must
• Demands high level of co-
ordination & efficiency
Limitations

21. Production planning and Control
represents the beating heart of any
manufacturing process and are essential for
customer delight and overall success of an
organization.
Conclusion