Production planning&

Control

Chapter 2.3

Process planning

Process planning refers to the preparation of detailed work plan. It determines the most economical method of performing an operation. Activities which are planned during process planning are:-

1. Selection of process

2. Selection of materials

3. Selection of machines, tools & equipments

4. Sequencing of operations

5. Grade of workmen required

6. Time required for each operation

Production control

It is the process that measures current performance and ensures that it is as per quality standards laid down in advance. Production control involves 3 steps:-

1. Dispatching

2. Follow up

3. Corrective action

Various types of control

1. Material control• Purchasing

• Receiving

• Issuing

2. Labor control

3. Machine utilization control

Production Planning & Control

• It comprises the planning , routing , scheduling ,dispatching and follow up functions in theproduction process so organized that movements ofmaterials, performance of machines and operationsof labor , however subdivided are direct andcoordinated as to quantity , quality , time and place.

• Planning:- Routing , Scheduling , Loading

Control :- Dispatching , Follow-up , Correctiveaction

Advantages of Production Planning & Control

1. Efficient use of resources

2. Economy

3. Coordination

4. Avoid bottlenecks

5. Inventory control

6. Customer satisfaction

7. Better public image

Elements of Production Planning & Control

1.1 Routing

1.2 Loading

1.3 Scheduling

1.4 Dispatching

1.5 Follow-up

1.6 Corrective measures

1.1 Routing

Routing deals with laying down of path along which materials are to travel in the process of production. Routing includes the following activities:-

1. The volume of production is decided

2. Machine capacity & machine characteristics are found out

3. On the basis of process sheet , the route sheets are prepared.

Routing determines what, how much , where and with which to be produced

1.2 Scheduling

Scheduling determines when various operations are to be performed . It leads to fixing up of starting and completion times for the various operations to be performed. The information required to draw production schedule include:-

a) Date of delivery specified by the customer

b) Time interval required to manufacture a component or part

c) Past production records

d) Availability of equipment , materials and specialized skills

Types of scheduling :-

• Master Scheduling

• Parts scheduling

• Machine loading schedule

1.3 Loading

Loading deals with the quantity of work assigned to a machine or a worker. The objectives of loading are as follows:-

i. To check the feasibility of production programmes

ii. To plan new work orders on the basis of space capacity available

iii. To balance the workload in the plant

iv. To assist in fixing of reliable delivery promises.

1.4 Dispatching

• Dispatching deals with setting the productive activities in motion through release of orders and instructions in accordance with previously planned timings as embodied in operation sheets route cards and loading schedules. Dispatching provides information for :-

i. Movement of materials to different workplaces

ii. Movement of tools & fixtures necessary for each operations

iii. Beginning of work on reach operations

iv. Recording of beginning and completion time

v. Movement of work in accordance with a routing schedule

vi. Control of progress of all operations

vii. Making of necessary adjustments in the release of instructions.

1.5 Follow-up or Expediting

• Expediting involves follow up of operations of various workshops to ensure that production of goods takes place as per predetermined schedules . The reasons for follow-up are :-

1. To record the flow of materials and tools

2. To record progress of production activities & make necessary adjustments

3. To compare & record the amount of work-in-process with schedule

4. To report the machine & manpower idleness & investigations the reasons for it

1.6 Corrective Actions

• Corrective actions is needed to make any system of production planning & control effective . By resorting to corrective measures , the production manager maintains full control over the production activities

Definition

Production planning essentially consists of planning production activities in an industrial enterprise before the actual operations start.

1. Routing

2. Scheduling

3. Loading or assignment of work