PRODUCTION PLANNING AND CONTROL

A review on Production Planning and Control - Definitions of production, production planning, production control, production management, steps involved in production planning, steps involved in production control

1. PRODUCTION PLANNING
AND CONTROL
BY
M. PRIYANKA
M. PHARMACY
SCHOOL OF PHARMACEUTICAL SCIENCES
JNTUK

2. CONTENTS
Introduction
Production planning
Process planning
Routing
Scheduling
loading
Production control
Dispatching
Follow up
Cost control
Quality control [email protected]
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3. INTRODUCTION
Production
planning
Production
control
Production
management
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4. DEFINITIONS
PRODUCTION:-
Transformationofrawmaterialstofinishedgoods
PRODUCTIONMANAGEMENT :-
Applicationofmanagement principlestotheprocessofproductioninanindustry
toproducedesiredgoodsineconomicalmannerbyco-ordinatingtheeffortsof
men,material&machine.
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5. PRODUCTIONPLANNING:-
Itisatechniquewhichhelpsinplanning&schedulingtheworkinthe
manufacturingplanttoobtainthedesiredqualityofproductswithoptimum
efficiency&atminimumcost.
PRODUCTIONCONTROL:-
Itensuresthattheworkisbeingdoneaccordingtotheplan
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6. PRODUCTION PLANNING
This phase includes a sequence of ideas to perform a task in an orderly manner by the
utilization of available manufacturing facilities.
Planning
involves
5 M’s
Money
Methods
Men
Machine
Material
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7. STEPS IN PRODUCTION PLANNING
PROCESS PLANNING
ROUTING
SCHEDULING
LOADING
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8. A.PROCESS PLANNING
Processplanningcanbedefinedasthepreparationofdetailedplansforthe
processrequiredtomanufactureaproductaseachmanufacturingprocess
consistsofnumerousoperations.
PROCESSPLANNINGREQUIRES
Quantityofworktobedone
Productspecifications
Sequenceofoperationstobeperformed
Timerequiredforeachoperation
Availabilityofmanufacturingfacilities
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9. STEPS INVOLVED IN PROCESS PLANNING
Process
selection
Selection
of raw
material
Selection
of
machinery
parts
Process
layout
Time
setup &
standard
operation
time
Documen
tation
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10. a)PROCESSSELECTION:-
Theoperationsselectedforaparticularprocessshouldbemosteconomical
Shouldsatisfytheproductspecifications
Selectionmainlydependsuponquality,quantity,timeperiod&machines
available
b)SELECTIONOFRAWMATERIALS:-
Shouldmeetqualitystandards
Shouldshowchemicalcompatibility
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11. c)SELECTIONOFMACHINERYPARTS:-
Properselectionofmachineryattachmentslikeinspectiongauges,jigs,etc.,is
necessaryforthesmoothfunctioningofmachines.Thishelpsinreducingthecosts
&durationofproduction&resultsinhighoutput.
d)PROCESSLAYOUT:-
Itdescribeseverystepofoperationaswellasthesequenceinwhicheach
operationistobecarriedout.
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12. e)TIMESETUP&STANDARDOPERATIONTIME:-
Theyshouldbeestablishedtocompletetheproductionwithinthetime.
f)DOCUMENTATION :-
Processplanningshouldbeclearlysummarizedindocumentssuchas
operation&routesheets.
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13. B.ROUTING
Routingistheprocessofdeterminingthesequenceofoperationstobecarriedout.
Determinesthepathforflowofworkrightfromtheselectionofrawmaterialsuntil
thecompletionofproductionoffinishedgoods.
Routingissummarizedinroutesheets.Preparedsheetsarethendispatchedtothe
productiondepartment.
Routesheetssummarizesprocesseslike
Descriptionofoperations
Sequenceofoperations
Typeofmachinery
Setuptime
Operationtime
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14. C.SCHEDULING:-
Schedulingconcernswithtimeelement.Itreferstothetimeframeofallproduction
activitiesthereforeschedulingisalsoknownastimephaseofloading.
OBJECTIVE:-
Toreducethetimeofproduction
Toensurethattheproductscanbedeliveredbeforetheduedate
TECHNIQUES:-
Masterschedule
Perpetualschedule
Orderschedule
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15. a)MASTER SCHEDULE
It contains information about all orders
On receiving the orders they marked on the master schedule depending upon their
delivery date.
It shows running production work & work ahead
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16. Master schedule chart
MASTER SCHEDULE FOR TABLET PRODUCTION DEPARTMENT
Maximum production:---hours
Minimum production:----hours
Week1 Week 2 Week3 Week 4
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17. b)PERPETUAL SCHEDULE
It provides only a gross picture of the schedule.
It involves
i.Preparation of load analysis sheet
ii.Preparation of Gantt load chart
PREPARATION OF LOAD ANALYSIS SHEET
LOAD ANALYSIS SHEET
Ordernumber
Load in hours or days
Section P Section Q Section R
A
B
C
15
10
20
10
15
12
10
08
15
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18. PREPARATION OF GANTT LOAD CHART: -
GANTT LOAD CHART
WEEK 1 WEEK 2 WEEK 3 WEEK 4
Section P
Section Q
Section R
Byknowingtheweeklycapacityofeachsection,theloadagainsteachsectionfora
certainnumberofweekscanbecalculatedandplottedonaGanttLoadChart.
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19. c)ORDER SCHEDULE
Order schedule can be prepared by plotting dates vertically & facility horizontally
on the chart.
Information required to prepare order schedule
Name of machines & their set up times
Total production time
Date on which the order is to be completed
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20. ORDER SCHEDULE CHART
ORDER SCHEDULE CHART
AUGUST
1 2 3 4 5 6 7 8 9
Facility P
FacilityQ
Facility R
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21. D.LOADING
Loadingistherelationshipbetweenloadandcapacityatwork
place.Itgivestheinformationaboutnumberofmachines,available,
theirspeed,capacity,capability.Ithelpstodetermineworkload
andactualcapacityofproduction.
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22. PRODUCTION CONTROL
Production control is the comparison between planning output
and output achieved.
STEPS INVOLVED IN PLANNING CONTROL: -
Dispatching Follow up
Cost
control
Quality
control
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23. A.DISPATCHING
Itistheprocessofissuingorders&instructionstoaparticularoperating
sectionofindustrytostarttheprocessingofagivenjobonanassigned
machineinaccordancewiththepreviouslyplannedsequence&timeas
detailedinroutesheets&schedulecharts.
Movementofmaterialstodifferentworkstations,movementofworkfrom
oneoperationtoanother&supervisionofworkcomesunderthiscategory.
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24. B.FOLLOW UP
It includes delays or deviations from the production plans
It helps to reveal the defects in
Routing
Scheduling
Loading
Dispatching
Misunderstanding of orders
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25. C.COST CONTROL
Thetotalcostfortheproductionofgoodsisdetermined&iscomparedwith
standardcosttocalculatethedeviationsaswellastofollowcorrective
action.
Itcanbecontrolledby
Reducingwastage
Valueanalysis
Inventorycontrol
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26. D.QUALITY CONTROL
Ithelpstoavoid&detectsthedefectsinproductionprocess&isolationof
defectivefinishedgoods
Finishedproductsareinspectedtoensuretheiracceptablequality
Qualitycontroltechniques
Statisticalqualitycontrol
Probabilityconcept
Poissondistribution
Samplinginspection
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27. REFERENCES
www.wikipedia.com
www.managementstudyguide.com
www.tandfonline.com
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28. “Always have a plan, and believe in it”
Priyanka Modugu
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