Production planning and control

1. PRODUCTION PLANNING AND CONTROL (PPC) MECHANICAL ENGINEERING (MUMBAI UNIVERSITY) SEMESTER-VII Academic Year-2020-21 VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR

2. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SYLLABUS OF PPC 2

3. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SYLLABUS OF PPC

4. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SYLLABUS OF PPC

5. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR EVALUATION OF PPC

6. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SYLLABUS OF PPC LAB

7. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR EVALUATION OF PPC

8. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MODULE-I CONCEPT OF PPC

9. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR 9

10. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR

12. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR TYPES OF PRODUCTION PLANNING AND CONTROL 12

13. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR FUNCTION OF PPC 13

14. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR Main Function of PPC  Material  Machines & Equipment's  Methods  Process planning(Routing)  Estimating  Loading & Scheduling  Dispatching  Expediting  Inspection  evaluation 14

15. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR OBJECTIVE OF PPC 15

16. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR FACTORS INFLUENCING PPC IN THE ORGANIZATION  VOLUME OF PRODUCTION  NATURE OF PRODUCTION PROCESSES  NATURE OF OPERATION  NATURE OF PRODUCTION  COMPLEXITY OF OPERATIONS  MAGNITUDE OF OPERATIONS 16

17. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MANUCATURING SYSTEM 17

18. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MANUCATURING SYSTEM

22. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR ORGANIZATION FOR PPC 22

23. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR PPC INTERNAL STRCTURE AS A PRODUCTION PROCEDURE 23

24. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR PRE-REQUISITES OF PPC  Data pertaining to Design  Data pertaining to Equipment's  Data pertaining to Raw materials  Data pertaining to tooling  Data pertaining to performance standards  Data pertaining to labour-Top level, Middle level & Lower level  Data pertaining to operating system 24

25. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MODULE -2 Forecasting, Aggregate planning & Capacity planning 25

26. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR NEED OF FORCASTING 26

31. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR METHODS OF FORCASTING 31

52. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR STRATEGIES FOR AGGREGATE PLANNING 52

57. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR CAPACITY PLANNING 57

58. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR FACTOR INFLUENCING EFFECTIVE CAPACITY 58

61. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MEASURES OF CAPACITY Design Capacity System Capacity Licensed Capacity Installed Capacity Rated Capacity 61

62. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR ROUGH CUT CAPACITY PLANNING 62

63. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR The concept behind the term Rough cut capacity is that it is the total amount of material required to fulfill the gross requirement of a company. It does not consider scheduled receipts or the on-hand inventory; it just calculates the rough cut amount needed to satisfy the gross-requirement. A rough-cut capacity planning includes charting out the,  staff-hours required to fulfill the job  the units required  several days that will be needed to complete the task eventually  the amount of material needs to be purchased. 63

64. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MODULE-3 INVENTORY CONTROL The amount of material, a company has in stock at a specific time is known as inventory or in terms of money it can be defined as the total capital investment over all the materials stocked in the company at any specific time. i.e. raw materials, in process materials, finished goods in store houses, spare parts, office stationary etc. 64

69. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR PURPOSE OF INVENTORY Inventories are needed because demand and supply can not be matched for physical and economical reasons. There are several other reasons for carrying inventories in any organization.  To safe guard against the uncertainties in price fluctuations, supply conditions, demand conditions, lead times, transport contingencies etc.  To reduce machine idle times by providing enough in-process inventories at appropriate locations.  To take advantages of quantity discounts, economy of scale in transportation etc.  To decouple operations i.e. to make one operation's supply independent of another's supply. This helps in minimizing the impact of break downs, shortages etc. on the performance of the downstream operations. Moreover operations can be scheduled independent of each other if operations are decoupled.  To reduce the material handling cost of semi-finished products by moving them in large quantities between operations.  To reduce clerical cost associated with order preparation, order procurement etc. 69

70. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR INFLUENCE OF DEMAND ON THE INVENTORY Following factors influences demand on inventory Customer demands Product demands Increase in sales Market research Excessive utilization of product 70

71. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR INVENTORY COSTS 71

72. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR WORK ORDER 72

88. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR IMPORTANT FORMULAE

89. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR ABC ANALYSIS 89

100. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MODULE-4 Process Planning and Line Balancing

104. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR Need for Process Planning  This is the planning strategy for manufacturing the part. It is defined as the activity that translates part design specifications from an engineering drawing into the manufacturing operation instructions required to convert a part from a rough to a finished state. It represents the link between engineering design and shop-floor manufacturing. It is a major determinant of manufacturing cost and profitability. The gap between CAD and CAM can be shortened considerably by developing better systems for process planning.  There are two levels of process planning  High-level planning'■ The planner identifies the machine able features (surfaces) of the part, groups them into set-ups, and orders these set- ups. The features to be cut in each of the set-ups, and the tools for cutting each feature.  Low-level planning- Specifying the details of performing each step that results from the first level such as choosing machines, cutting conditions (speed and feed), type of fixture, cost and time estimates, etc.

106. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR DOCUMENTS IN PROCESS PLANNING  Customer drawing  Process sheet  Flow process charts  Master production schedule

107. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR IMPORTANCE OF PROCESS PLANNING  Optimum utilization of manufacturing utilities.  Planning processes of manufacturing according to product specifications.  Best way to utilize m/c for particular process  Strategic decisions to plan and adapt production of every single components  Best interface between design and manufacturing

108. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR TYPES OF PROCESS PLANNING  Manual Process planning

114. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR DIFFERENCE BETWEEN MANNUAL AND COMPUTER ADDED PROCESS PLANNING

119. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR LINE BALANCING

140. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR LARGEST CANDIDATE RULE

143. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR MODULE-5 Production Scheduling and Sequencing

155. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR INPUTS FOR SCHEDULING  Process inputs  Product specifications  Product Design-bill of materials, tolerance chart, surface irregularities  Master production schedule

156. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR LOADING DEVICE  Loading Devices

157. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SCHEDULING DEVICE  Charts  Process sheet  Master production schedule  Flow production charts  Control charts

158. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR FACTORS INFLUENCING SCHEDULING  Internal factors I. Finished goods inventory II. Process intervals III. Types of machines available IV. Availability of personnel V. Availability of material VI. Manufacturing facility

159. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR FACTORS INFLUENCING SCHEDULING  External factors I. Consumer demands II. Consumer delivery dates III. Dealer and retailer inventories

166. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR GANTT CHART

197. VIVA INSTITUTE OF TECHNOLOGY, VIRAR PPC by PROF. MANOJKUMAR SEQUENCING

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