2. 2
Learning Objectives of this Chapter
VTC
To Understand the process of production planning &
control(PPC)
To know about Sales forecasting and its methods
To Have good knowledge on process planning
To Know about Dispatching, routing and scheduling
4. 4
3.1 PPC Introduction
VTC
All manufacturing and service operations require planning and
controlling
PPC is a co-ordination of series of functions according to a plan
Economically utilize the plant facilities and
Regulate the orderly movement of goods through the entire
manufacturing cycle at a predetermined rate."
6. 6
3.1 Understanding PPC
VTC
Anticipates the possible difficulties
before the start of actual production
Done in advance so that the
production is carried out in most
economical and the best way
Production Planning
7. 7
3.1 Understanding PPC
VTC
The planning of industrial operations
involves
What Work Shall Be Done,
How The Work Shall Be Done
When The Work Shall Be Done
Who will be doing the work
Production Planning
8. 8
3.1 Understanding PPC
VTC
Ensures that the programmed
production is constantly
maintained
Producing the products of right
quality in right quantity at the
right time.
Production Control
9. 9
Collecting information regarding product specifications etc.
Controlling men and material
Preparing Route and Schedule Charts
Monitoring the progress during production
Forecast quantity and quality of future work
Standardizing the Production
3.1 PPC Objectives
13. 13
Sales Forecasting
VTC
What is forecasting?
What is Sales Forecasting?
Estimate of the sales potential for a future period.
Helps the management in determining the
Realization of revenues, manufacture programme,
Requirement of men, materials and machines.
Forecasting must be accurate, simple, easy to
understand and economical.
14. 14
Forms the basis for sales, production and material budget.
Helps in formulating policies
Helps in deciding about plant expansion
Helps in preparing production and purchasing schedules
Helps to determine the production volume
Guides in marketing production and other activities .
Sales Forecasting - Uses
16. 16
Sales Forecasting - Factors
VTC
What is forecasting?
Competition
Assess the demands for the
product
Analyzing existing and new
competitors and their products.
Opinion of customers in
comparison with similar products
17. 17
Sales Forecasting - Factors
VTC
What is forecasting?
Changes in technology
Introduction of sophisticated
machinery, material etc.
Products of latest technology
or models which are preferred
in the market.
Innovation on software and
hardware
18. 18
Sales Forecasting - Factors
VTC
What is forecasting?
Changes in government policies
Different rules regarding tax
policies, import policies, export
policies, which will have a direct
impact on sales.
Ex: GST Implementation, Plastic
usage reduction, upgradation of
BS4 vehicles
19. 19
Sales Forecasting - Factors
VTC
What is forecasting?
Factors relating to Industry
These are internal factors within the industry like
Change In The Capacity Of Machines,
Change In The Prices,
Change In The Method Of Manufacturing Etc.
20. 20
Steps in Forecasting
Select the items to be forecasted
Gather the data
Determine the time horizon of the forecast
Make the forecast, validate and implement it
Determine the use of the forecast.
22. 22
3.3 Process Planning
VTC
What is forecasting?
What is a Process?
A process is a series of actions
which are carried out in order to
achieve a particular result.
Process is a set of interrelated
tasks that transform inputs into
outputs
23. 23
3.3 Process Planning
VTC
What is forecasting?
What is a Process Planning?
Systematic determination of the methods by which a product is
to be manufactured, economically and competitively.
Subsystem responsible for the conversion of design data to work
instruction
Intermediate stage between design the product and
manufacturing it.
24. 24
3.3 Process Planning
VTC
What is forecasting?
What is a Process?
A process is a series of actions
which are carried out in order to
achieve a particular result.
Process is a set of interrelated
tasks that transform inputs into
outputs
25. 25
3.3 Process Planning
VTC
What is forecasting?
What is a Process Planning?
Systematic determination of the methods by which a product is
to be manufactured, economically and competitively.
Subsystem responsible for the conversion of design data to work
instruction
Intermediate stage between design the product and
manufacturing it.
27. 27
3.3 Process Planning
VTC
What is forecasting?
Process Planning Organization
Process planning is a staff activity.
It is a department or alternatively a sub group
Co-ordinates with sub groups such as plant layout, tool
design etc.
Plans all the process more effectively and economically
Tends to utilize the resources more effectively.
28. 28
Information Needed
VTC
.
Quantity of work
Product specification.
Quality of work to be completed.
Availability of equipment and tools.
Availability of man power
Sequence of Operations
Names of equipment
Standard time for each operation.
When the operation will be performed
29. 29
Process Planning Procedure
.
Preparation of working drawings.
Deciding to make or buy.
Selection of manufacturing process.
Machine capacity and machine/equipment selection.
Selection of materials and bill of materials.
Selection of jigs, fixtures and other attachments.
Operation planning and tooling requirement.
Preparation of documents such as operations and route sheets
etc.
31. 31
Process Planning - Example
.
Reg.No
4/9/2018 1H 4/9/2018 1H 5/9/2018 1H 6/9/2018 4H 7/9/2018 3H 7/9/2018 1H
PRE- TOOLING OPERATIONS
CNC
STARTED DATE
COMPLETION DATE
ESTIMATED HOURS
ACTUAL HOURS
ASSEMBLY/BENCH
WORK
INSPECTION
HEAT
TREATMENT
WIRE
EDM
PUNCH
HOLDER
MS
NETTUR TECHNICAL TRAINING FOUNDATION
PROCESS PLANNING CHART
TURNING
JIG
BORING
/
CO-
ORDINATE
DRILLING
MILLING
2
SPARK
EDM
Component/ Part
DRG NO -
SL NO
Description &
Raw Material
size
Material
MILLING
2
GRINDING
1
32. 32
3.4 Despatching
VTC
What is forecasting?
What is Despatching?
Despatch function executes planning function.
It is concerned with getting the work started.
Despatching ensures that the plans are properly implemented.
It is the physical handing over of a manufacturing order to the
operating facility
33. 33
3.4 Despatching
VTC
What is forecasting?
Who is a despatcher?
Dispatcher transmits order to the various
shops
A dispatcher is familiar with the productive
capacity of each equipment.
He always keeps an eye over the progress of
order which move at different speed on
different routes.
34. 34
3.4 Despatching
VTC
Necessary authority and conformation is given for:
Movement of materials to different workstations.
Movement of tools and fixtures necessary for each operation.
Beginning of work on each operation.
Recording of time and cost involved in each operation.
Movement of work from one operation to another in
accordance with the route sheet.
Inspecting or supervision of work
35. 35
3.4 Despatch Procedure
VTC
The various steps of dispatch procedure for each operation are
listed below in sequence.
Store issue order
Tool order.
Job order
Time Ticket
Inspection Order
Move Order
36. 36
3.4 Despatching Procedure
VTC
What is forecasting?
Stores Issue Order
Authorize store (department) to
deliver required raw material.
So that Production starts on
time
37. 37
3.4 Despatching Procedure
VTC
What is forecasting?
Tool Order
Authorize store to release the
necessary tools.
The tool can be collected by the
tool room attendant
Necessary tools has to planned
while process planning itself
38. 38
3.4 Despatching Procedure
VTC
What is forecasting?
Job Order
Instruct the worker to proceed
with the operation.
The operations are executed
according to process planning.
Instructions are given in the job
card
39. 39
3.4 Despatching Procedure
VTC
What is forecasting?
Time Ticket
Record the beginning and
ending time of the operation
and forms the basis for worker’s
pay.
Also helps to overlook the plan
versus actual timing of each
operation
40. 40
3.4 Despatching Procedure
VTC
What is forecasting?
Inspection order
Notify the inspector to carry out
necessary inspection
Record and report the quality of
the component.
Also helps to understand the
quality of each machine, man
and process
41. 41
3.4 Despatching Procedure
VTC
What is forecasting?
Move order
Authorized the movement of
material and component from
one facility(machine) to another
for further operation
42. 42
3.4 Despatch Procedure
VTC
Other Factors which need to be taken care
All production information should be available beforehand.
Various order card and specification drawing should be ready.
Equipment should ready for use.
Progress of various orders should be properly recorded on the
Gantt chart display board.
All production record should be properly maintained
44. 44
Centralized Despatching
VTC
A separate central despatching department is employed
This orders directly to the work attain.
It maintains a full record of the characteristics and capacity of
each equipment and work load against each machine.
The orders are given to the supervisor, who runs his machine
accordingly.
In most of the case the supervisor can also give the suggestions
as regards loading of men and machine under him.
45. 45
Centralized Despatching - Advantages
VTC
A greater degree of overall control
Effective coordination between different facilities is possible.
It has greater flexibility.
Changes in schedule can be implemented rapidly without
upsetting the whole system.
Progress of order can be readily assessed at any time
46. 46
Decentralized Despatching
VTC
Here Shop supervisor perform the functions.
He decides the sequence of handling deferent order.
He dispatches the order and material to each equipment
In case he suspect delay with due reasons of the same he
inform the production control department.
47. 47
Centralized Despatching - Advantages
VTC
Much of the red tape is minimized
Shop supervisor know best about his workshop.
Elaborate report and duplication of posting can be avoided.
Communication gap is reduced
It is easy to solve day to day problems
It keeps the natural urgency of a section to be in sufficient.
48. 48
3.5 Routing
VTC
What is forecasting?
What is Routing?
The path for the raw material till it becomes finished product
It indirectly derives the method of manufacturing
It determines, when, where and how the product is
manufactured.
49. 49
3.5 Routing
VTC
Routing depends on the type of industrial layout and determines
the best and cheapest sequence of operation.
Different Types of Industries
Continuous industry
Assembly industry
Job order industry
50. 50
3.5 Routing
VTC
What is forecasting?
Route Sheet
The sequence of operations and descriptions of the operations
with time is indicated in route sheets;
Prepared by the planning department and rigidly followed..
51. 51
Production Planning and control
VTC
What is forecasting?
Other Factors related to PPC
Scheduling.
Material Requirement Planning
Work force Planning
Capacity requirement Planning
Production control using JIT
Shop floor Planning
