A SEMINAR REPORT ON

ROLE OF PRODUCTION AND PLANNING CONTROL

Submitted in partial fulfillment for the award of

the Degree of Bachelor of Technology in
Mechanical Engineering

Submitted by:

HIMADREE SINGH

B.Tech Final Year ( Mechanical Engineering )

Guided by:

Dr. B. L. Salvi

Associate Professor, Mech. Engg.

DEPARTMENT OF MECHANICAL
ENGINEERING

College of Technology and Engineering

Maharana Pratap University of Agriculture and
Engineering, Udaipur-313001 Rajasthan
April,2024

i
 DECLARATION BY STUDENT

The seminar work compiled in this report titled ‘Role of Production and Planning

Control’, submitted for the award of degree of Bachelor of Technology in Department of

Mechanical Engineering of Maharana Pratap University of Agriculture and Technology,

Udaipur (Raj.), is compilation work of literature carried out by me under the supervision of

Dr. B. L. Salvi, Associate Professor, Department of Mechanical Engineering, College of

Technology and Engineering, Udaipur. The contents of the seminar report are prepared by

me and either partially or fully, have not been submitted or will not be submitted, as it is to

any other Institute or University for the award of any degree or diploma.

I, declare that I have adequately cited and referenced the original sources used in this

seminar report. I also declare that I have adhered to all principles of academic honesty and

integrity and have not misrepresented or fabricated or falsified any idea/data/fact/ source in

my submission.

Date- 23.04.34
Name of Student – Himadree Singh
Entry/Reg. No.:2020/CTAE/326
Final Year B.Tech.(Mech)

ii
 DEPARTMENT OF MECHANICAL ENGINEERING
College of Technology and Engineering
Maharana Pratap University of Agriculture and Engineering
Udaipur-313001 Rajasthan

CERTIFICATE

This is to certify that seminar report entitled ‘Role of Production and Planning

Control’ has been prepared and is submitted by Ms. Himadree Singh, student

of IV Year B.Tech. (Mech.), Session: 2022-23, Semester – Second, in partial

fulfillment of the requirement for award of the Degree of Bachelor of

Technology in Mechanical Engineering from Maharana Pratap University of

Agriculture and Technology, Udaipur-313001 Rajasthan.

Date: 23.03.24

Dr. B. L. Salvi
Associate Professor
Department of Mechanical Engineering
College of Technology and Engineering
Udaipur-313001

iii
 ACKNOWLEDGEMENTS

First of all I thank the God Almighty for His grace and mercy that enabled me in the
finalization of this seminar. I would like to express my sincere gratitude to Dr. B. L. Salvi ,
my seminar advisor, for their invaluable guidance, constructive criticisms, and support
throughout this project. Additionally, I extend my appreciation to all my teachers and fellow
mates for their assistance and help. Their contributions have greatly enriched the content and
quality of this report.

Date: 23.04.24

Himadree Singh

B.tech Final Year (Mech. Engg.)

iv
 CONTENTS

Pages

CERTIFICATE…………………………………………………………….…………iii

ACKNOWLEDGEMENTS………………………………………………..…………iv

CONTENT……………………………………………………………………………v

INTRODUCTION……………………………………………………………………vi

PRE PLANNING, PLANNING CONTROL…………………………………………vii

PROJECT PLANNING AND PREPLANNING………………………………….…viii

STAGES OF PPC……………………………………………………………….….…x

ROLE OF PPC IN OPERATIONS MANAGEMENT………………………………xii

PPC’S INTERACTION WITH DEPARTMENTS………………………….……….xiv

LITERATURE REVIEW…………………………………………………………….xvi

DISCUSSION………………………………………………………………………..xvii

CONCLUSION……………………………………………………………………….xix

REFERANCES……………………………………………………………………….xx

v
 1. INTRODUCTION

Production and Planning Control (PPC), intervenes into many departmental and industrial
operations. PPC functions look after the manufacturing activities. PPC comprise the planning,
routing, dispatching in the manufacturing process so that the movement of material,
performance of machines and operation of labour however are subdivided and are directed
and coordinated as to quantity, quality, time and place.

Planning and control are two basic and interrelated managerial functions. They are so
interrelated that they can be and often are considered as being one function. Planning is the
preparation activity while control is the post-operation function. Both of them are so closely
related that they are treated as Siamese twins. Planning sets the objectives, goals, targets on
the basis of available resources with their given constraints. Control is the integral part of
effective planning. Similarly control involves assessment of the performance, such
assessment can be made effectively only when some standard of are set in advance. Planning
involves setting up to such standard.

The controlling is made by comparing the actual performance with these present standard and
deviations are ascertained and analyzed. Production is an organised activity of converting raw
materials into useful products but before starting that work of actual production, production
planning is done in order to anticipated possible difficulties and decide in advance as to how
the production should be carried out in the best and economical way. Since mere planning of
production is not only sufficient, hence management takes all possible steps to see that
project or plan chalked by the planning department are properly adhered to and the standards
set are attained in order to achieve it, control over production is exercised. The aim of
production control is to produce the products of right quality, in right quantity at the right
time by using the best and least expensive methods.

Fig.1.1 A creative of PPC 1

 2. PREPLANNING, PLANNING & CONTROL
The activities of preplanning, planning and control may be considered to take place in a time
sequence. The preplanning is completed before production commences. Planning takes place
immediately before production starts and control is exercised during production.

2.1 PREPLANNING:

It is the procedure followed in developing and designing a work or production of a

developing and installing a proper layout or tools. It may be involved many functions of the
organization and draws upon forecasting, product design, jigs and tool design, machine
selection and estimating to enable proper design to be made. In short, preplanning decides
what shall be made and how it shall be made. In respective manufacture a large uneconomic
output could be produced if preplanning is omitted. It is also important in one of the
operations such as setting up a new plants as preplanning can identify and avoid probable
costly errors.

2.2 PLANNING :

This stage decides where and when the product shall be made. It includes the sequencing of
operations viz outing and the time schedule for manufacturing viz scheduling. It also states
procedures for material planning and supplies, machine loading and deliveries. To perform as
functions properly it will need past records of performance and to control statistic which may
be obtained from pre-planning, cost control or progress.

2.3 CONTROL :

This refers to the stage of ensuring that the planned action is in tact carried out. Control
initiate the plan at the right time using dispatching and there after control makes appropriate
adjustments through progressing to take care of any unforeseen circumstances Production
Planning And Control 3 that might arise. It includes measurement of actual results,
comparison of the same with the planned action and feeding back information the planning
stage to make any adjustments required. The pattern of control is seen in material control,
machine utilization, labour control, cost control and quality control.

2
 3. PROJECT PLANNING OR PREPLANNING :
Before starting every project its planning is done. Planning a project is a very important task
and should be taken up with great care as the efficiency of the whole project largely depends
upon its planning. While planning a project each and every detail should be worked out in
anticipation and should be considered carefully considering all the relevant provisions in
advance. Project planning consists of the following important steps.

1) Market Survey :
Market survey in a broad sense, is a commercial survey for the suitability of business
it provides necessary statistics helpful for forecasting planning project.

2) Project Capacity :
Capacity of the project must be decided considering the amount of money which can
be invested for particular type of product and how the money which can be invested
for a particular type of product and how the money can be arranged. While deciding
the capacity of the project, following factors must be considered.
i) Demand of the product in the market.
ii) Quantity of power, water, land and raw material available.
iii) Nature of product.
iv) investment capacity.

3) Selection of Site :
While selecting the site, technical, commercial and financial aspects should
thoroughly be considered. Site should be selected in two states; in first stage general
location for factory should be selected in this location. Important factors to be
considered for the selection of site.
i) General location of the factory.
ii) ii) Selection of exact site.

4) Plant Layout :
One of the most important aspects of production system design is layout of facilities
primary object of these is to optimize the arrangements “ 4 m’s” and supporting
services.

5) Design and Drawing :

After deciding the product its detailed drawing are prepared so that no doubt is left
for future. Detailed specifications for raw materials and finished product should be
decided carefully along with the specification of the machines required for their
manufacture.

6) Material requirement :
The list of materials required for manufacture is prepared from the engineering
drawings. This list is known as “Bill of materials” part list”. 3
7) Operation Planning :
Work of this is to select the best method of manufacturing, so that the wastage of
material, labour, machine and time can be eliminated, to have more production with
less fatigue. This work is done in two phases, namely. Method study is conducted to
eliminate the wastage due to ill directed and inefficient motions. Time study is the
exact estimation of time and is very essential for correct pricing.

8) Machine loading :
Number of machines to be installed in a plant should be decided very carefully while
planning, proper care should be taken to find out the machining time for each
operation as correct as possible, so that arrangement for full utilization of machines
can be made and machines loading program is prepared accordingly.

9) Sub-contract consideration :
With the development of technology and specialization, it is difficult to manufacture
all the components in the same factory, due to fact that specialized machines plants
and workers. The decision about particular item, whether to purchase or to
manufacture, is taken by planning department after making a through study of the
relative merits and demerits.

10) Equipment Requirement :

After knowing the number of equipments, their accessories and tools required, cost
data can be collected to give and idea of capital requirement.

11) Organisational Layout and staff Requirement :

Layout of organisation is decided by considering the nature of work, type of industry
size of industry, etc and in line of above the stalls are appointed.

12) Material Handling :

The material handling problems must be studied before the erection of the factory
building and plant layout.

13) Budgeting :
Budgeting is forecasting and preplanning for a particular future period using past
experience and market trends.

14) Cost Calculation

Total cost of a product is calculated by adding the expenses incurred during the period
on a product.

15) Procurement of Finance :

Generally large industries manage their block capital through partners and
shareholders. While the working capital arranged through ‘shares debentures, loans
and banks. 4
 4. STAGES OF PPC

Fig. 4.1 Stages of PPC

Planning:

The planning department receives comprehensive information from managers regarding the
amount to be produced and the dates when delivery to consumers has been guaranteed. This
allows for detailed planning of productive activities. The engineering department also
provides the planning department with the required engineering and drawing specifications.

5
Routing:

Routing requires deciding on the work's direction and also the sequence in which particular
tasks will be accomplished. Routing's purpose is to find the most efficient and cost-effective
sequence of occurrences. When creating the route card, keep in mind that the plant's
equipment are running at full capacity, and people and other resources are being used to their
full potential.

Schedule:

Scheduling is referred as the process of estimating the time of completion and operation, and
the time needed to finish the entire series as intended, while taking into consideration all
important factors. It entails the creation of a timetable that details the overall time required to
create a product as well as the time spent at each equipment and procedure.

Loading:

A load is an amount of work, and loading is the process of distributing that quantity of work
to the processes required to create each item. Assigning jobs to work centres or equipment
inside the work centers is referred to as loading.

Dispatching:

Dispatching refers to the act of transmitting something to a certain location. It refers to

completing all measures necessary to carry out the production schedule outlined in the
routing and scheduling processes

Follow-Up (or Checking the Progress):

The control component of production planning and control is follow-up. It comprises

analyzing if work is moving as planned and how far deviations from norms have occurred,
along with taking corrective measures to restore law and order.

Inspections:

Follow-up is a control component of production planning and control. It includes assessing

whether or not work is proceeding according to plan, as well as evaluating how far deviations
from norms have happened and taking corrective measures to restore order. 6
Correction:

Other phases in the production control process are evaluated, and changes are made as
needed. Routings, job scheduling, and even talks with workers who are taking those extended
breaks are all part of this

ROLE OF PPC IN OPERATIONS MANAGEMENT

Because of its interactive function and interdependency with almost every sector of the
manufacturing process, production planning and control in operations has a lot of breadth and
importance. Figure demonstrates this very clearly. Production’s planning and controlling
(PPC) not only offers the entire approach to the manufacturing and production division, but
also supervises and controls every step of the working environment, getting feedback from
the product / process design and engineering divisions. PPC interacts with all other
departments in the manufacturing department in both directions, including production and
service, attaining and catalogue, construction and replacement, quality controller,
manufacturing engineering, and work studies.

Attaining and Catalogue Management:

Scheduling for the timely acquisition of fresh materials, machineries, and replacement
portions in the correct amounts and stipulations from the factual source at the correct price.
Other tasks related with materials include acquiring, storing, inventory controls,
regularization, diversity decrease, target costing, and examination.
Industrial and Assemblage:

Production’s planning and controlling entails organizing and planning the production process
in general. It includes, for example, routing, scheduling, dispatch, inspections, and
coordinating, as well as material management, techniques, tools, and operating hours. The
eventual goal is to establish the supplies and movements of constituents and labour, as well as
machine usage and associated operations, to achieve the intended production outcomes in
terms of quality, quantity, time, and location.

Marketplace Prediction:

The marketplace prediction is useful for production’s planning and management because it
forecasts futures demand patterns for manufactured goods. Work shift rules, plans for
increased or decreased manufacturing activity, and potential plant expansions are frequently
dependent on market projections, which impact the production planning and control group's
planning.

Engineering Stipulations:

When blueprints and bills of constituent’s form portion of the packed directions provided to
the workshop over controlling workplace, they have been used by planning and control.
Gathering all important data for a shop orders in a complete unit, which comprises the
process development sheets, blueprint, purchase orders, routing template, and maybe the
order's production process, became one careful planning strategy.

Quality Control:

A good PPC will guarantee that quality standards are followed and that the product is of high
quality. In terms of capacity utilization and inventory control, PPC is invaluable to the
entrepreneur. More significantly, it increases the speed and quality of his responses. As a
result, successful PPC adds to company success in terms of interval, superiority, and price .
The manufacturing and engineering industry, which operates in a highly dynamic and ever-
changing environment, now plays a critical role. Today's and tomorrow's production systems
must not only operate efficiently at low costs, but also adapt quickly and flexibly to market
changes, creating environmentally friendly products of high quality. Simulations are the
major techniques utilized in the implementation of digital’s enterprise technologies (DET).
The direct connection of simulation with production’s planning and schedule (PPS) or
industrial implementation schemes is not common in conventional simulation applications
(MES). The continual short-term refining (detailed scheduling) of the initial master planning
process is carried out in the MES, where the planning time intervals are days or hours.
PPC’s INTERACTION WITH DEPARTMENTS

• SALES AND MARKETING

Sales and marketing department directly interacts with customers ,once it receives Purchase
order (PO) from customer they generate a Sales Order (SO). Further they inform PPC
department about the demand (SO and forecast). PPC department works as per SSD of
demand and provides order readiness. Next 3 months demand discussed in S&OP (Sales and
Operations Planning).

• PROCUREMENT

PPC provides MRP(Material Requirement Plan) to Purchase department for material buying
against SO. Purchase informs the PPC back with material lead time and availability. It
remains in direct contact with supplier and coordinates accordingly about supplier PO.

• PRODUCTION

Production provides their manufacturing capacity information to PPC. Based on which PPC
generates a weekly MPS(Master Production Schedule) and issue jobs for firm manufacturing
for next 4 weeks. It takes timely updates about the job.
• HUMAN RESOURCE MANAGEMENT

Based on S&OP and MPS, PPC circulates 3 months man power requirement to HR and in
return HR informs about the availability of strength.

• NPD (R&D)

New Product Development is responsible for generating new products in company, PPC
interacts by implementing pilot process and defining attributes in system for the same.

• MANAGEMENT

PPC prepares performance measurement reports about all the work done in operations and
submits it to them for regular monitoring and future decision making.
LITERATURE REVIEW
Roliand Van Dierdonck and Jeffrey G. Miller provide a contingency model for explaining
aggregate variations in production planning and control specified requirements between
businesses. A company's functional requirements are linked to its competitiveness and
environment, as defined in terms of data processing system investments and organizational
technologies. The accessibility of the model's ideas, including its prospective usage, are
shown by an assessment of data from a small number of enterprises and a panel of
executives. The main concept of existing study is that a good control over production systems
should represent a company's economic scheme consistently. This link is made in the model
that was developed to represent this hypothesis. The production planning job is deduced from
the modest scheme as the first stage. The second stage is to determine the suitable system
characteristics for the job, including the grade of information’s processing system
involvements (IPSI) and resources to keep .

Maurice Bonney analyses the present status of Production Planning and Control (PPC),
highlights certain technological and system developments that have happened in recent years,
and connects them to the market demand. PPC is being expected to be more dynamic and
provide greater management of resources and delivery performance in order to successfully
adapt to these internal and external changes. Some of the specifications that the new PPC
systems must meet have been specified. To satisfy these criteria, it is proposed that a greater
knowledge of how various elements impact the performance of PPC systems is necessary, as
well as that administrative processes be improved. PPC is examined in terms of its
quantitative, administrative, and behavioral components. A framework for creating an action
and research objective is offered .

Vaidyanathan Jayaraman et al. discussed the features of the remanufacturing environment

were discussed Remanufacturing is quickly gaining traction as a valuable resource for waste
reduction and ecologically responsible manufacturing. For a broad variety of products,
companies are found it to be a profitable method while also boosting their image as
ecologically friendly. In this setting, the remanufacturing firm's production’s planning and
controlling functions is investigated. The study is assessed in the different decision’s taking
domains that make up the production’s planning and controlling functions. There are still
numerous zones where study is lacking. It is highlighted that the production’s planning and
controlling functions lacks an overall integrated structure and models. It's also worth noting
that most businesses are still dealing with these issues and don't have any official processes in
place to deal with them. Prototypes and outlines based on the challenges and demands of
these re-processing companies are needed .

Cheng Wang and Xiao-Bing Liu discussed about integrated production’s planning. The
purpose of this article is to propose a multi-objectives production’s planning optimization
model, which is defined as the integration of production’s planning and controlling for
business manufactured administration modelling and fabrication. A multiple objectives
production scheduling optimization’s prototype is presented based on a study of ERP
planning system flaws and drawbacks, as well as relevant research and literature. Multiple
performance management goals, including on delivering, manufacturing balance, stock, and
overtime manufacturing, are included in the model's examination scope, furthermore to net
demand and potential, so that industrial processes can be managed and organized maximum
among different objective. The findings of the study are that manufacturing small company
product development management considers not only potency and machinery, but also a large
array of performance measurement goals in the manufacturing processes, and that using a
multi-objective optimization model to optimize enterprise production administration and
monitoring can be efficient.

Nikos I. Karacapilidisa and Costas P. Pappis focus on the Master Production Scheduling
issue and provide an interactively model-based solution for production management in
textiles manufacturing system. The scheduling of these systems becomes extremely difficult
due to the industry's unique characteristics, which include multiple stage processes with
numerous units per stage, variable planning prospects, and varying production’s needs for
each stage. The aforesaid features are evaluated, and their influence on the production’s
control systems is discussed, in addition to a complete explanation of the collection of
modules that make up the system, as well as their interrelationships. The system is also linked
to MRP-II and Optimized Production Technology, two very well recognized production’s
control schemes. Data structure diagrams are used to demonstrate the system's characteristics,
while Appendix A shows the entire method for the master production’s preparation modules
in pseudo-code method, as well as the relevant section of the databases
DISCUSSION
To fulfill orders on schedule, manufacturing planning is critical. Customers will not be
satisfied if employees are unaware of stock quantities, available workstations, or task
schedules. Production planning is essential whether the individual is a new producer who is
oiling the equipment for the first time or an experienced manufacturer who is delivering
thousands of goods. Production plans, including scrums and monthly plans, guarantee that
resources are used to their full potential. Charts and graphs can handle a few production
orders, but for major manufacturing companies, the complexity skyrockets.

Production planning assists in the purchasing of raw materials based on the number of
manufactured goods to be generated. Stockpiles, cash flow, sales, and distribution are all
impacted. Production’s planning is essentially the planning of resources for delivering goods,
while production control is the regulating of the production system to accomplish objectives
as efficiently as possible.

Manufacturing control is more about keeping an eye on the production line and intervening
when things aren't going as planned. The term "production’s planning and controlling"
simply refers to the utilization of all of these ideas in order to achieve an efficient production
line.

PPC serves a variety of purposes, including improved organization for on-time delivery to
customers, optimum resource usage, reduced inventory investment, avoided resource
wasting, enhanced efficiency, and cost savings by identifying and eliminating faults. The
study found that the kind of product and the manner of manufacture have an impact on the
PPC.
CONCLUSION
Over the last several decades, the manufacturers industry as an entire has seen significant
variations in terms of gauge, intricacy, and expertise, and this is true of most present high-
tech manufacturing applications in engineering, semiconductors, aircraft, and automobiles.
Manufacturers must create high-quality goods at a cheap cost while maintaining adequate
flexibility to satisfy quickly changing consumer needs in order to stay profitable.
Production’s planning and controlling is a critical function that allows a company to have
prominence and controls upon all elements of production operations.

PPC is a subject of research in in of itself, with simulation approaches proving to be the most
useful procedures for investigating and evaluating industrial difficulties. The assessment
focuses on state-of-the-art imitation approaches in PPC in this review article to illustrate its
relevance to current manufacturing challenges.

PPC advantages, processes in production’s planning and controlling, variables impacting

production’s planning and controlling, function of PPC in business management, and PPC's
interconnectedness with other parts of the manufacturing process are all discussed in this
study. According to the findings, future research should focus on a thorough examination of
hybrid techniques for adapting to a variety of PPC challenges, as well as the development of
trustworthy analytical simulation tools for effective PPC implementations
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