ppc module ii

8/10/2019 Ppc Module II

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MODULE-II

Production Planning: Objectives,

Characteristics, Process Planning.

Production Control: Objectives, Production

Control Systems, Principle and Procedureof Production Control.

Routing: Objectives, Procedure, Route

Sheet.



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Production Planning

• Definition: Production Planning can be defined as “ the

means by which a manufacturing plan is determined,information issued for its execution, and data collected andrecorded, which will enable the plan to be controlled throughall its stages”.

• Functions:- Investigation about the complete details and requirements of theproduct to be manufactured.

- Pre-determination of future achievements

- Planning the design of products going to be manufactured

- Planning about the quality and quantity of materials which are to beconsumed

- Planning the quality of products to be manufactured

- Planning about the sequence of operations

- Planning the capacity of equipments

- Planning about the internal transportation.



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Objectives of Production Planning

• To determine the capacity of manufacturing departments

and to plan systematically coordinated and relatedproduction activities to meet sales requirements.

• To plan for manufacturing requirements like materials sothat they are available in right quality and quantity of theright time.

• To translate sales orders in to the orders on the worksdepartment

• The coordination with different departmental groups sothat line balance of activities is maintained

• To promote full utilization of plant capacity• To maintain a record of material in stock in such a way so

as to enable to anticipate future requirements

• Prepare schedule of requirements.



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Basis of Good Production Planning

(Characteristics)

1. Organisation:a) Recognition by management of the need for Production

planning and be prepared to delegate authority and responsibility

b) To have co-operative effort, the supervisory level personnelmust recognize that the work schedule is purely an extension of

function specialisation. Due to this facility, they devote more time tothe activities for which they are best suited.

2. Personnel:

a) They must understand the scheduled operations

b) They should be trained specially to suit the particular system tobe adopted.

c) They must have the interest and aptitude in doingthe required work.



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(Characteristics)………..

3. Standardisation:a) Material purchased or fabricated

b) Tools and Equipments

c) Method of Operations

d) Method of Remuneration for workers

e) Quality standards and inspection procedures

f) Set up of organisation

g) Reporting on progress of manufacture showingcomparison with the planned schedules.



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4. Information about Productive Capacities andRequirements:

a) Knowledge about the components to be manufactured

b) Knowledge about production machine with specifications

c) Knowledge about manufacturing time required for

sequence of operation for parts, components and final assemblyd) Knowledge about material requirements in stores,

total requirements, time required for getting the newly purchasedmaterial

e) Quantity of materials consumed per time

f) Knowledge about labour employed and productive capacities foreach type of labour

g) Manufacturing operation of each part

h) The availability of required tools, Jigs and fixtures for eachcomponents.



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5. Planning for Controlled Production:Planning of Production operations should ensure thatthese operations proceed under controlled conditions inthe specified manner and sequence.

Controlled conditions include:• Production

• Appropriate control of materials

• Equipment

• Processes and procedures• Computer software

• Personnel

• Associated supplies and

• Utilities and environments



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There are some other factors also effect the goodProduction planning and control:

• Complete Specification in details

• Advice of job study man for routing of work

• Job study data in case of new operation

• Getting information for every machine about the amount ofwork to be allocated on the machine

• Determination of alternative machine to achieve flexibility

• Layout of the plant, production centers and machines

• Equipment and arrangements for conveying andtransportation of materials

• Methods and facilities for storage and issue of materials

• Degree to which product is simplified or standardized

• Degree to which operations and processes are simplified



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Advantages of Production Planning

• Better service to customer in promised deliverydates

• Fewer rush orders in the plant and less over time

• Lower inventory of work-in-process

• Less finished stock required to give the sameservice to customer

• Better control of raw material inventory, whichcontributes to more effective purchasing

• More effective use of equipment• Less loss of time by workers awaiting for

materials, which improve their morale

• Less wastage of materials



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Process Planning

• Process Planning is determining the most economical

method of performing an activity.

• Process Planning develops the broad plan of

manufacturing a product or a component.

• The following information are required for carryingout process planning:

1. Quantity of work to be performed

2. Detailed specification of the product

3. Quality of Work4. Availability of Equipment, tools and manpower with period

5. Sequence of operations to be performed

6. Standard time for each operation



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Steps involved in Process Planning

• Most economical process is selected depending upon

current production commitments, delivery date,quantity to be produced, quality standards.

• Selection of materials, right quality, shape and size of

raw materials.

• Selection of Jigs- fixtures and special attachments• Selection of cutting tools

• Selection of inspection gauges

• Make the process layout indicating sequence of

operation

• Documentation process i.e for operation, route sheet

etc.



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Process Planning Characteristics

Type of Layout

Equipment

Work RoutingProduction Run

Volume

Job Design

Capacity Concern

Loading Concern

Continuous SystemIntermittent System

Eg. Job Shop

General Purpose

To Different areasOften short

Sometimes Small

Often Broad

Individual Equipment

Work-M/c Balance

Eg. Assembly line

Special Purpose

Along similar pathOften long

Often large

Often narrow

Production line

Assembly line Balance

Process Planning Considerations in Intermittent

and Continuous Production Systems



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Process Planning Tools

• Assembly Charts• Operations Charts

• Flow Process Charts

• Man-machine and Activity Charts

• Computations facilities



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Assembly Charts

A1

A2

A3

A4

A5

A7

A8

A9

A6

A10

SA1

SA2

SA3

Assembly Chart for Electric Heater

Assembly Bracket to Body

Assembly Switch to Body

Electrical Connections

Install Cord

Assemble and Install heater element

Test

Assemble end plate to Body

Assembly end caps to Body

Install Screen

Final Inspection

1. Body

2. Bracket

3.Insulator

4.Switch

5. Internal Wiring

6. Cord

7. Resistor Wire

8. Porcelain Rod

9. Copper end Caps

10. End Plates

11. Plastic End Caps

12. Screen



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Operations Process Chart& Flow Process Chart

Operation Process Chart:• Similar to Assembly Charts

• They include specifications of component parts

• They also provide operating time and inspection Times

• Thus they provide more complete instruction on how toproduce an item

Flow Process Chart:

• Similar to Operation Process chart

• They also include Non-Productive Activities like

Storage (

), Delay (D) and Transport (

)

• They also provide operating time and inspection Times

• They also provide Distance traveled



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Man-Machine and Activity Charts

• Graphic devices for modeling the simultaneous

activities of a worker and the equipment• They help to identify idle time and cost of both

workers and machines

• Process Planners can then analyze alternative

worker-machine combination and determine themost efficient arrangements

• Worker-machine charts show the time required tocomplete tasks that makes up a work cycle.

• Most economic work cycle time can be derivedfrom this chart.



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Production Control

Definition:- According to Henry Fayol, “ ensuring that

all which occurs is in accordance with the rulesestablished and the instructions issued”.

Objectives:

Issuing the necessary orders to the concernedpersonnel, so that the production plans may be put into effect

To arrange necessary items like materials, machines,tools, jigs, fixtures and man-power in quantity andquality at a time as planned

To see that orders (instructions) are followed so thatgoods with required quality and quantity may bemanufactured and delivered at the promised time.



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Fields of Production Control

• Control of Activities

• Control of Materials movement

• Control of Tools Availability

• Control of due date

• Control of Quality produced• Control of Quantity produced

• Control of Labour efficiency

• Control of Scraps• Control of quantity disbursed

• Control of Priority

• Control of Cycle time etc.



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Information and Data required by

Production Control Department

• Material with its specification and quantity withrequirement schedule

• Availability of materials in store, and the status of purchase orders

• Engineering drawing and specifications of the productsto be manufactured

• Output capacity of the production machines

• Operation method based on method study

• Sequence of operations, as finalised by the production planning department

• Job analysis to know the particulars to be done with

skill and type of personnel needed.



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Progress Control

Steps involved in developing a ProgressControl System are:

– Setting up a system to watch and record the

progress of production. This can be done through

bar charts, Curves, Gantt Charts or through atabular statement

– Making a report of the progress of work

– Transmission of report through written, oral or

electronic (telephone, fax, teleprinters etc.) system

– Interpretation of information and decision making

– Taking corrective action



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Routing

Definition:- May be defined as the selection of path

which each part of the product will follow while beingtransformed from raw materials to finished products.Path of product will also give sequence of operation to

be adopted while being manufactured.

In other words, routing means determination ofmost advantageous path to be followed fromdepartment to department and machine to machine tillraw material gets its final shape.

While converting raw material into requiredgoods, different operations are to be performed and theselection of a particular path of operations for each

piece is termed as ‘ Routing’



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Analysis in Routing Process

• Analysis of type of work to be done on

product or parts• Operations required to do the work

• Sequence of Operations

• Where the work will be done• Proper classification about the personnel

required

• Analysis of the machines for doing the workRouting provides the basis for scheduling,

dispatching and follow-up.



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Factors Responsible for Proper Routing

• Process analysis should be done

• In case of assembly, product analysis of differentcomponents should be done

• Analysis of materials required should be done

• Analysis for the quantity required for each component

• Order of preference of various products must be found out• Finding out the place of operation and operations to be

performed at different stages of operation

• Knowledge of machines and operations to be used

• Knowledge about the quantity of materials to be consumedin different stages with regard to the time consumed indifferent operations and space requirement for materialmovements



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Route Sheet

• It deals with specific production order generally madefrom operation/work sheets. One sheet is required foreach part or component of the order.

• This includes:-

(a) Number and other identification of order

(b) Symbol and identification of part© Number of pieces to be made

(d) Number of pieces in each lot if put through in lots

(e) Operation data, which consists of:

(i) list of operations on the part(ii) department in which operations are to be performed

(iii) machine to be used for each operation

(iv) fixed sequence of operation, if any

(v) Date at which the job must be completed, determined from the

operation sheet.

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