1 production control
TRANSCRIPT
-
8/12/2019 1 Production Control
1/25
The function of Production Control is to produce productswith minimum total cost in the required planned delivery
timeframe.
The production plan should permit one to anticipate the
progress of the production of any and every individual productfrom the receipt of the raw material to the shipment of the
order.
The production plan should also permit one to anticipate the
itemized and total cost of producing and delivering goods .
Overview of Entire Production Control System
B F Tech VI,January2012
-
8/12/2019 1 Production Control
2/25
The efficiency of the production control performance is equal
to the precision of the time and cost anticipation .
The greater the deviation from the scheduled time and cost
figures, the poorer the production control performance.
Production control is composed of a sequence of five
activities
B F Tech VI,January2012
-
8/12/2019 1 Production Control
3/25
1)Analyzing:
Process of determining the quality specifications of the
product.
The analysis provides the specifications for the following
elements of production:
Raw materials
Production equipment and tools
Production personnel that will yield the durability, utility and
emotional appeal (style factors) required for the garment .
B F Tech VI,January2012
-
8/12/2019 1 Production Control
4/25
This presents the quality measuring scale for the product.
- The analysis also gives the basis of quantitative production
capacity of each operation, job or process.- This is one of the requirements for forecasting the anticipated
load of production per unit time.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
5/25
2) Forecasting:
It is the process of estimating the future sales volume, the rate
of sales and the rate of delivery
3) Planning (Organizing and Scheduling):
Activity of organizing the sequence of communications and
material processing.
Every production process must be initiated or curtailed by
some communication without which there could be no
precision scheduling.
Scheduling is the second half of the planning activity; it adds
the when to organizing what and where
B F Tech VI,January2012
-
8/12/2019 1 Production Control
6/25
4)Routing:
It consists of assigning the who to planning and executing the
what, where and when
5)Controlling:
It is the activity with which the production manager inspects
and corrects the execution of the production plan. It is theaction that must be taken to change the plan whenever
production is behind the planned schedule because of
improper planning, unforeseen emergencies or unpredicted
occurrences.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
7/25
Production controlinvolves people and activities thatstrive toplan, schedule, coordinate , monitorwork flow
and control production with in manufacturing factory.
Its duties include reviewing master production schedules
and work orders, and revising schedulesaccording toavailability of workers, materials and equipment
B F Tech VI,January2012
-
8/12/2019 1 Production Control
8/25
Production controlalso aids the supervisor in guiding his/
her line toward an optimum level of productivityin order
to assure that scheduled completion datesare achieved.
Production controlassures that products are being
manufactured on a balanced and timely program.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
9/25
What does a Production Control; system entail?
Generally split into two main subsystem: Production planning and Resource planning
Production Control and Cost Production reporting;
Main objectives of the Production planning system are:
1) To assist in the planning and recording of overall production
requirements.
2) To assist in the translation of the overall requirement in to a
production schedule
3) Material Requirement and planning (MRP) to enable the
user to correctly schedule the ordering of raw materials
B F Tech VI,January2012
-
8/12/2019 1 Production Control
10/25
4) Resource Capacity planning to enable the user to analyze
physical capacity of men and machines against capacityrequired.
5) To provide facilities to plan the production schedule in detailand ensure that production resources are fully utilized.
6) To launch production jobs with required documentation (jobcards, Material requisition form, bundle tickets), the materialsrequired to be drawn for these jobs, and the activities to be
performed in the production process
7)To capture and monitor details of work in progress andproduction quantities
B F Tech VI,January2012
-
8/12/2019 1 Production Control
11/25
8) To maintain a tracking history of job progress
9) To report an exceptional conditions to ensure that jobs
progress according to plan
10) To capture and record the true cost of production and to
record abnormal costs such as reprocessing costs etc
11)To report on the costs and efficiencies of complete jobs in the
following categories:
12)Planned quantities versus quantities actually produced
The ultimate objective of all these activities is the organizationof the supply and movement of materials and labor, machine
utilization and related activities in order to help manufacture
customer orders (or stock) in the most efficient time , at the
lowest possible cost and with the highest qualityB F Tech VI,January2012
-
8/12/2019 1 Production Control
12/25
Functions of Production Control:
Clear distinctions between Production control and actual
manufacturing Methods installed for the organized production control must be
definitely adapted to the particular factories in which they areinstalled
Production control is a facilitating service to manufacturingmanned by staff personnel. It coordinates all of the necessaryproduction information and production aids, includingmethods , times , materials and attachment
It directs and checks on the course and progress of work, and
closes the records when work on an order has been completed. Production control and engineering department has separate
responsibility
B F Tech VI,January2012
-
8/12/2019 1 Production Control
13/25
WHY PRODUTION CONTROL?
As customer bases grow, there are more and more stylevariations with in product groups.
Control procedures are determined by several conditioning
factors:
1)Varied or repetitive character of operations
2) Nature of manufacturing processes
3) Magnitude of operations
B F Tech VI,January2012
-
8/12/2019 1 Production Control
14/25
1)Varied and repetitive operations:
Variety of operations complicates the problem of planning andcontrol, whereas repetitive operations, since they reducevariety, tend to simplify the problem
Variants between continuous production of a single
standardized product and the completely special orderbusiness on the other
B F Tech VI,January2012
-
8/12/2019 1 Production Control
15/25
Manufacturing to order
Manufacturing for stock
Variations in capacity of machines for
different classes of work Degree to which subassembly exists
Occurrence of customer orders containingspecific delivery dates
Receipt of orders for many small lots
B F Tech VI,January2012
-
8/12/2019 1 Production Control
16/25
2)Nature of Manufacturing:
Production control is at minimum where a single
homogeneous product is treated by a fixed sequence of
processes in a continuous flow e.g coca cola bottles
Very little production control is required in these factories
since it has already been embodied in the product and
equipment itself
B F Tech VI,January2012
-
8/12/2019 1 Production Control
17/25
In contrast to the continuous industries are repetitive operations
in factories making many products and lots at the same time.
To bring these together in proper sequence, at the right time andat the right place pushes planning and control functions to the
utmost.In customer manufacturing, less accurate planning is possible
than when manufacturing for stock.
Custom orders usually require a certain time , over and aboveactual operating time to pass through the factory.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
18/25
In mixed stock and custom manufacturing, either stock or
custom orders may be the main feature
A certain amount of stock manufacturing to fill gaps in
machine loading is a useful accompaniment of custom work.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
19/25
3)Magnitude of operations:
In a small scale enterprises, control is more informal because itis more personal and direct.
The degree to which the performance of any activity must be
decentralized depends upon the scope of operations and the
convenience of their location.In large factories , activities associated with warehousing,
processing operations and custody of fished goods must of
necessity be carried on in numerous locations.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
20/25
Production planning and control
There are certain basic elements in a system or productionplanning and control.
Production forecasting/ planning:
It determines what manufacturing must produce, the quantities
involved , when the products must be available and the timeand quantity requirements for materials , parts, labor and
facilities
B F Tech VI,January2012
-
8/12/2019 1 Production Control
21/25
Production control:
Promotes effective factory operation through its control of
activities with in production department itself. This control
may involve routing, the decision on facilities and sequence
for each operation, and follow up. The importance of control functions, and procedures will vary
from factory to factory.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
22/25
Routing:
It begins at the determination of the sequence of operations
Routing can be performed properly only be people who arethoroughly familiar with the character of the work to be done
and with the resources available for doing it
Preparation of operational breakdowns and production orders
Loading and scheduling
B F Tech VI,January2012
-
8/12/2019 1 Production Control
23/25
Costs and benefits of Production control
Since production control is being paid for, either as a
specialist function or a hidden cost, it is necessary to decide
which method is most efficient.
The production control workload varies in proportion to the
number of orders it processes rather than the hours of
production load .
The costs of poor production control are low rates of
production, high costs, high inventory of materials in process
and finished stock, poor morale and disappointed customers.
B F Tech VI,January2012
-
8/12/2019 1 Production Control
24/25
Benefits and advantages of Production control:
1) The Consumers
Increased productivity
Better values
On time deliveries
2) The Producers
Adequate wages
Stable employment
Job security
B F Tech VI,January2012
-
8/12/2019 1 Production Control
25/25
Improved working conditions
Increased personal satisfaction
Security of investment
Adequacy of return
3) The Community
Economic and social stability
5) The Nation:
Security
Prosperity
B F Tech VI,January2012