Chapter1 1

Planning & Control

Planning & Control
Chapter 1
Production /
Production /
Operations
Operations
Production Planning
Production Planning
& Control
& Control
Chapter1 2
Production/Operations
Production/Operations
Planning & Control
Planning & Control
Production is a process whereby raw material is
converted into semi finished products and thereby adds
to the value of utility of products, which can be
measured as the difference between the value of
inputs and value of outputs.
Production function encompasses the activities of
procurement, allocation and utilization of resources.
The main objective of production function is to
produce the goods and services demanded by the
customers in the most efficient and economical way.
Therefore efficient management of the production
function is of utmost importance in order to achieve this
objective.
Chapter1 3
Production/Operations
Production/Operations
Planning & Control
Planning & Control
Production/Operations Planning involves the
organization of an overall manufacturing system to
produce a product.
The various activities involved are:
Designing a product
Determining the equipment & capacity
requirements
Designing layout of physical facilities.
Designing material handling system
Designing sequence of operations
Chapter1 4
Factors determining Production
Factors determining Production
Planning Procedures
Planning Procedures
The three major factors determining production planning
procedures are:
1.Volume of production:The amount & intensity of production
planning is determined by the volume and character of the
operations & nature of manufacturing process.Production
planning is expected to reduce manufacturing costs.
2.Nature of production Process:In job shop ,the production
planning may be informal and the development work methods is
left to individual workman who is highly skilled
3.Nature of operations:Detailed production planning is
required for repetitive operations for example continuous
production of single standardized product
Chapter1 5
Production
Production
Planning System
Planning System
There are two interrelated subsystems in the production
planning system
Product Planning System
Process Planning System
A generic business process, which has
Data embedded systems at all levels, namely,
Plant operation level,
Physical variable controls level.
Process control levels, and at
Information control level
resulting in vertical and horizontal system interfaces
between its all external and internal system modules,
and
Chapter1 6
Production
Production
Planning System
Planning System
Which is characterized by the real world feedback
information in respect of:
(a) customer requirements, which are becoming
increasingly local and instant, product needs,
(b) process costs and capabilities,
(b) input orders, innovation desired, and
(c) questions, etc.presents itself as an an open
system.
This leads to modeling the business process as
integral to a close loop information and control system.
Chapter1 7
Production Control
Production Control
Importance of Control function:
Provide the production of parts,assemblies & products
of required quantity and quality at the required time
Co-ordinate ,monitor,and feedback to manufacturing
management,the result of production
activities,analyzing and interpreting there importance&
taking correct actions
Provide optimum utilization of all resources
Achieve the broad objectives of low cost production
and reliable customer service
Chapter1 8
Production Control
Production Control
Benefits of Control function:
Improvement in profit through:
1. Maintenance of balance inventory of material
2. Balanced and stabilized production
3. Maximum utilization of equipment
4. Minimum investment in inventory
5. Reduction in set up cost
6. Reduction in scrap
7. Minimum investment in inventory
Competitive advantage
1. Reliable delivery to customer
2. Shortened delivery schedule to customer
3. Lower production costs
Chapter1 9
Elements of Production Control
Elements of Production Control
1. Control of Planning:
2. Control of Materials
3. Control of tooling
4. Control of manufacturing capacity
5. Control of activities
6. Control of Quantity
7. Control of material handling
8. Control of due dates
9. Control of information
Chapter1 10
Elements of Production Control
Elements of Production Control
The production Control System consists of a group
of procedural elements that operate as a whole
to fulfill four functions
Means of setting the system in motion such as
production orders
Methods to determine Lead time for production
Methods to control & monitor production
What,where& How work is to be done
Techniques for measuring & recording data on
machine utilization
Chapter1 11
Factors Determining Production
Factors Determining Production
Control procedures
Control procedures
Nature of Production: The manufacturing firms are
classified as Intermittent,continuous,or composite
production firms,depending upon length of processing time
Complexity of operations: Generally Complexity increases
with increase in the variety of operations
1.Number of ultimate parts in the product
2.No of different operations
3.Extent to which processes are dependent on previous
operations.
4.Variation in production rates of machines used in the
process
5.Receipt of may small lot orders
Chapter1 12
Factors Determining Production
Factors Determining Production
Control procedures
Control procedures
Magnitude to operations:
The size of operation,(time taken to complete
operation)and the distance traveled by the parts from
operations to operations are important in establishing proper
production control procedures.
Generally the need is greater for centralized production
control organization and the formal procedures as the size of
the operations increases and dependent operations are more
physically separated
Chapter1 13
Factors Determining Production
Factors Determining Production
Control procedures
Control procedures
Following factors need to be considered before making
a choice of manufacturing
process.
a) Effect of volume/variety: This is one of the major
considerations in selection of manufacturing process.
When the volume is low and variety is high, intermittent
process is most suitable and with increase in volume
and reduction in variety continuous process become
suitable. The following figure indicates the choice of
process as a function of repetitiveness. Degree of
repetitiveness is determined by
dividing volume of goods by variety.
Chapter1 14
Factors Determining Production
Factors Determining Production
Control procedures
Control procedures
b) Capacity of the plant: Projected sales volume is the
key factor to make a choice between batch and line
process. In case of line process, fixed costs are
substantially higher than variable costs. The reverse is
true for batch process thus
Jobbing
Batching
Line
Process
Degree of
repetitiveness
Quantity
Many
Chapter1 15
Factors Determining Production
Factors Determining Production
Control procedures
Control procedures
c) Lead time: - The continuous process normally yields
faster deliveries as compared to batch process.
Therefore lead-time and level of competition certainly
influence the choice of production process.
d) Flexibility and Efficiency: - The manufacturing
process needs to be flexible
enough to adapt contemplated changes and volume of
production should be large enough to lower costs.
Hence it is very important for entrepreneur to consider
all above mentioned factors before taking a decision
regarding the type of manufacturing process to be
adopted as for as SSI are concerned they usually adopt
batch processes due to low
investment.
Chapter1 16
Objectives of Production Planning
Objectives of Production Planning
& Control
& Control
1. To deliver Quality goods in required quantities
2. To ensure maximum utilization
3. To ensure production of Quality products
4. To maintain optimum inventory levels.
5. To maintain flexibility in manufacturing operations
6. To coordinate between labor & machine.
7. To ensure effective cost reduction and cost control
8. To prepare production schedule
9. To produce effective results for least total cost
10. To remove bottlenecks in production
Chapter1 17
Role of Production Planning
Role of Production Planning
& Control in Operations Management
& Control in Operations Management
There are a variety of production /operations management
responsibilities such as:
1.Product Design
2.J ob & process Design
3.Equipment Selection & replacement
4.Labor skills
5.Input material selection
6.Plant selection and layout
7.Scheduling steps of the plan
8.Implementing & controlling the schedule
9.Operating the production system
Chapter1 18
Role of Production Planning
Role of Production Planning
& Control in Operations Management
& Control in Operations Management
Operations
Implementation
Evaluation
Control
Replanting
Tactical Planning
Strategic Planning
Chapter1 19
Scope of Production Planning
Scope of Production Planning
& Control
& Control
Production Planning and control encompasses the
following areas:
1. Materials
2. Methods
3. Machine & equipment
4. Manpower
5. Routing
6. Estimating
7. Loading & scheduling
8. Dispatching
9. Expediting
10. Evaluating
11. Cost Control
Chapter1 20
Principles of Production Planning
Principles of Production Planning
& Control Functions
& Control Functions
1. Types of production determines the kind of production
planning & control
2. Number of parts involved in the product
3. Complexity off PPC function
4. Time is common denominator for all scheduling activities
5. PPC permits management by exception
6. Cost control should be a by product of PPC function
7. The size of the plant has relatively little to do with the
type of ppc system needed
8. The highest efficiency in production is obtained by
manufacturing the required quantity of a product
Chapter1 21 Chapter1 21
Phases in Production Planning
Phases in Production Planning
& Control Function
& Control Function
1. Planning Phases
a) Pre planning: Activity involves product planning &
development ,resource planning ,Plant planning
b)Active Planning: involves planning for quality
2. Action Phase : Execution or implementation phase
includes dispatching and progressing function
3. Control Phase : Includes status Reporting Material
control, Tool control,Quality control
Chapter1 22 Chapter1 22
Main Functions of Production
Main Functions of Production
Planning & Control Department
Planning & Control Department
ProductionPlanning & Control
ProductionPlanning
Estimating
Routing
Scheduling
ProductionControl
Dispatching
Inspection
Evaluating
Chapter1 23
Levels of Production Planning
Levels of Production Planning
Management control fits in between
Strategy formulation & Task control
Strategy formulation focuses on long run &
Task control on short run activities
Strategy formulation uses rough
approximations of future & Task control uses
current accurate data
Chapter1 24
Levels of Production Planning
Levels of Production Planning
Strategy
Formulation
Management
Control
Task
Control
Goals, Strategies,policies
Implementation of
Strategies
Efficient,& effective
Performance of individual
tasks
Activity
Nature of end Product
Chapter1 25
Management Control
Management Control
Management control is the process by which managers
influence other members of the organization to
implement the organizations strategies.Several aspects of
this is amplified below.
Management Control Activities
Planning What the organization should do.
Co-Ordination The activities of several parts of
organization
Communicating information
Evaluating information
Deciding What if any action should be taken
Influencing people to change there behavior
Chapter1 26
Framework for Strategy Implementation
Framework for Strategy Implementation
Implementation mechanisms Implementation mechanisms
Strategy
Performance
Organizational
Structure
HR
Management
Management
Control
Culture
Chapter1 27
Strategy Formulation & task control
Strategy Formulation & task control
Strategy formulation Management control
Task Control
Acquire Business Introduce new product Coordinate order entry
Enter new Business Expand a plant Schedule Production
Add direct mail selling
Determine ad budget
Book 6v Commercials
Decide magnitude &
direction of research
Control research
organization
Run individual
Research project
Device inventory
Speculation policy
Decide
inventory levels
Reorder an item
Chapter1 28
Production Planning Function
Production Planning Function
The main functions of production planning are:
Estimating: Decides the quantity of products to
be produced & cost involved on the basis of
sales forecast
Routing :This is process of determining
sequence of operations to be performed in the
production process
Scheduling : Involves fixing priorities for each
job and determining the starting time & finishing
time
Loading:Loading facility or work center&
deciding or machine which job is assigned to
which work center
Chapter1 29
Production Control Function
Production Control Function
The main functions of Production Control are:
Dispatching:
Setting of production activities in motion through release
of orders
Providing movement of Raw material
Issuing J ob orders
Issue of Drawings ,process sheets,job log sheets to
machine & assembly shop
Obtaining inspection Schedules

Expediting /follow up/ progressing
Expediting /follow up/ progressing
Expediting
Expediting ensures that the work is carried out as per
plan and delivery schedules are met
Chapter1 30
Limitation of PPC Function
Limitation of PPC Function
Production planning functions are based on
certain assumptions or forecast of customer
demand,plant capacity.
Employees may resist changes in production
Production planning process is time consuming.
Production planning is difficult when when the
environmental factors change rapidly,such as
Technology changes, Government
policies,Customers taste regarding fashion.
Chapter1 31
Measuring Effectiveness of
Measuring Effectiveness of
PPC Function
PPC Function
There are four specific areas in which effectiveness of
PPC function can be measured

Delivery
Delivery:This can measured by finding out the number
of deliveries effected on time and those delayed over
period of time

Inventory levels
Inventory levels.The value of average inventory held
annually.

Production & operations management
Production & operations management: Comparison of
planned & actual production indicates the performance
of PPC function
The expenditure incurredfor carrying out various
functions of PPC department
Chapter1 32
PPC In different
PPC In different
Production Systems
Production Systems
PPC in job Production
job production Job production involves producing a
one-off product for a specific customer. J ob production
is most often associated with small firms (making
railings for a specific house, building/repairing a
computer for a specific customer, making flower
arrangements for a specific wedding etc.) but large firms
use job production too. Examples include:
Designing and implementing an advertising campaign
Auditing the accounts of a large public limited company
Building a new factory
Installing machinery in a factory
Benefits and disadvantages
Key benefits of job production include:
Chapter1 33
PPC In different
PPC In different
Production Systems
Production Systems
work is generally of a high quality
a high level of customization is possible to meet the
customer's exact requirements
significant flexibility is possible, especially when
compared to mass production
workers can be easily motivated due to the skilled nature
of the work they are performing
Disadvantages include:
higher cost of production
requires the use of specialist labor (compare with the
repetitive, low-skilled jobs in mass production
slow compared to other methods (batch productionand
mass production)
Chapter1 34
PPC In different
PPC In different
Production Systems
Production Systems
Batch Production
This approach to design productionproducing individual
designs in limited quantitieswas common amongst many
smaller companies or craft workshops for much of the 20th
century, allowing them to respond quickly to different
commissions and market opportunities without the necessity
of being tied down to the relatively inflexible and expensive
technologies associated with the modes of mass-production
Fordism.
With the rise of Computer-Aided Manufacturingsystems
larger manufacturers have also been able to be more
flexible and swiftly responsive to the increasingly diverse
consumer demands of the global market place.
Chapter1 35
PPC In different Production Systems
PPC In different Production Systems
This ability to produce smaller production runs
had the added economic advantage of dispensing
with the need for large storage areas to hold stock
and was an integral part of the J ust in Time
manufacturing and distribution systems that were
introduced increasingly from the 1980s
Batch production is a manufacturing process
used to produce or process any product in batches,
as opposed to a continuous productionprocess, or a
one-off production.
Batch production is popular in bakeries and in
the manufacture of sports shoes, pharmaceutical
ingredients, inks, paints and adhesives.
Chapter1 36
PPC In different
PPC In different
Production Systems
Production Systems
There are inefficiencies associated with batch
production. The production equipment must be
stopped, re-configured, and its output tested before
the next batch can be produced. Time between
batches is known as 'down time'.
Batch production is useful for a factory that
makes seasonal items or products for which it is
difficult to forecast demand.
Chapter1 37
PPC In different
PPC In different
Production Systems
Production Systems
There are several advantages of batch production;
it can reduce initial capital outlay because a single
production line can be used to produce several
products.
Also, companies can use batch production as a
trial run. If a retailer buys a batch of a product that
does not sell then the producer can cease
production without having to sustain huge losses.
Other types of production include: assembly line,
job production, continuous, cell, and project.

Chapter1 38
PPC In different
PPC In different
Production Systems
Production Systems
Mass Production Manufacturing or processing of
uniform products in large quantities using interchangeable
parts and machinery. Mass production is either a wholly
automated process or a series of short, repetitive
procedures.
mass production
Application of the principles of specialization, division of
labor, and standardization of parts to the manufacturing of
goods on a large scale. Modern mass-production methods
have led to such improvements in the cost, quality,
quantity, and variety of goods available that the largest
global population in history is now sustained at the
highest general standard of living ever.
Chapter1 39
PPC In different
PPC In different
Production Systems
Production Systems
Mass Production is a system of manufacturing based on
principles such as the use of interchangeable parts, large-
scale production, and the high-volume Assembly Line.
Although ideas analogous to mass production existed in
many industrialized nations dating back to the eighteenth
century, the concept was not fully utilized until refined by
Henry Ford in the early twentieth century and then
developed over the next several decades.
Ford's success in producing the Model T automobile set
the early standard for what mass production could achieve.
As a result, mass production quickly became the dominant
form of manufacturing around the world, also exerting a
profound impact on popular culture.
Chapter1 40
Requirement of effective PPC
Requirement of effective PPC
System
System
Sound organization structure with mechanism of
proper delegation of authority.
Information feedback system
Standardization of material,tool,equipment &
manufacturing process.
Trained personnel
Flexibility to accommodate changes
Appropriate management policies
Accurate assessment of lead times
Plant capacity should be adequate to meet the
demands
Chapter1 41
Make or Buy analysis
Make or Buy analysis
The capacity of a firm to produce finished
product depends on at what stage the firm begins
the manufacturing process
Make or buy decisions are basically questions of
specialization& vertical integration
The product design specializes product structure
which indicates number of sun units & piece part
that comprise a product.
The process engineer has to make decision Make
or buyafter studying drawings of parts &
assemblies .
Chapter1 42
Plant Planning & Facility Planning
Plant Planning & Facility Planning
How to establish the long range production
capacity to produce the products /services for a
firm is a critical part of setting operations strategy.
Facilities planning refers to the determination of
how much of long range production capacity is
needed.,where production facilities should be
located,and layout & characteristics of these
facilities.
Importance of Plant Planning
Plant planning is along range planning begin with
the choice of suitable location
Chapter1 43
Plant Planning & Facility Planning
Plant Planning & Facility Planning
The right plant enables the firm to produce the
desired quantity & quality of the products
The choice of right plant helps to minimize the
capital investment.
It produces job satisfaction to employees
Objectives of Plant Planning
To set optimum plant system that will provide
highest efficiency
Effective integration of all factors such as
man,material,& machine
Chapter1 44
Plant Planning & Facility Planning
Plant Planning & Facility Planning
Objectives of Plant Planning
Logical work flow & smooth sequence of
operations
Compactness to minimum movement of material
& labor and space
Provisions of facilities for future expansion
System flexibility to adopt changes in product
design
Satisfaction ,safety and convenience to all
employees
Chapter1 45
Plant Planning & Facility Planning
Plant Planning & Facility Planning

Scope of of Plant Planning
Scope of of Plant Planning
Selection of production of system and plant
design
Design of plant building
Manufacturing process design
Selection of equipment & machinery
Design of plant layout and shop layout
Selection of material handling system.
Design of communication System and control
system
Chapter1 46
Production Planning
& Control
End Of
Chapter 1