35
CONTENTSTopic page no.1. Title Summary 62. Introduction 73.
Company Profile 8 - 214. Objectives of the Study 225. Production
Function 23-246. Steps in PPC 25-30 7. Problems with Traditional
Production Planning and Control 31-3210. Production Planning and
Control at R.L. MASAALA 33-4611. Research Methodology 4712.
Interpretation of Data 48-5713. Findings 5814. Conclusion 5915.
Recommendation 6016. Bibliography 6117. Annexure 62-63
Project Title HOW TO SMOOTHING THE PROCESS OF PRODUCTION,
THROUGH PLANNING AND BETTER SUPERVISION
Title Summary: The project has been developed to identify the
need and importance of PPC i.e. Production Planning and Control in
manufacturing industry. Production planning is done with the
objective of coordination of materials with suppliers, efficient
utilization of people and machines, efficient flow of materials,
and communication with customers.
Various activities are supported by Production Planning and
Control like- Materials Planning, Purchasing, Raw Material,
Inventory Control, Capacity Planning, Scheduling Machine and
People, WIP Inventory Control, Coordinate Customer Orders, Finished
Goods Inventory Control.
Production planning and control facilitates in various ways
like- optimum utilization of capacity, inventory control, ensures
quality, and economy in production time.
Production Planning is accompanied with Control Mechanism to
ensure desired results. Results are compared with plans, if any
deviation is found revision of plan is done. Hence, Production
Control is an adjusting process, providing corrective measures for
planned development.
INTRODUCTION
India is known as The home of spices. No Indian meal is
considered complete without the tangy and delectable flavor of
Indian spices, locally known as Masala. Indian spices are famous
all over the world for their gastronic value and them known to
possess high medicinal values. There is no other country in the
world that produces as many kinds of spices as India. Some of the
most widely consumed spices in the country inter alia include:
chilli, cinnamon, cumin, curry leaf, fennel, asafetida, basil, bay
leaves, cardamom-small, cardamom-large, ginger, mustard, bishops,
weed, cassia, celery, clove, coriander, fenugreek, garlic, mint,
onion, parsley, pomegranate, turmeric, tamarind, pepper, poppy,
rosemary and vanilla. The climate of the country is found suitable
for growing almost all spices. India produces 25 lakhs tone to 30
lakhs tonne of spices annually. India produces spices of different
categories worth around Rs.14, 000 crore. In terms of volume India
accounted for 46 percent and 23 percent in value of global spice
trade. India accounts for 25-30 percent of worlds pepper
production, 35 percent of ginger and about 90 percent of turmeric
production.
There are few things that permeate Indian life so completely as
spices. The aroma, colour, taste and texture of the astonishing
varieties of spices in India nourish a rich variety of cuisines and
cultures.
There are few things that permeate Indian life so completely as
spices. The aroma, colour, taste and texture of the astonishing
varieties of spices in India nourish a rich variety of cuisines and
cultures.
Earlier, spices were chosen, measured, pounded and mixed, all in
the kitchen. It took hours to prepare these spice recipes passed
down by generations. Today, millions of homes enjoy the same
authentic taste and aroma of traditional delicacies, with Everest's
perfect blend of pure spices. These blends even bring the regions
closer by providing the authentic taste of other regional cuisines,
in the convenience of a pack, at home.
Cardamom
Cardamom
True Cardamom (Elettaria cardamomum)
Scientific classification
Kingdom:Plantae
(unranked):Angiosperms
(unranked):Monocots
(unranked):Commelinids
Order:Zingiberales
Family:Zingiberaceae
Genera
AmomumElettaria
Cardamom(orcardamon) refers to several plants of the
similargeneraElettariaandAmomumin thegingerfamilyZingiberaceae.
Both genera are native toIndia,Pakistan,NepalandBhutan; they are
recognised by their small seed pods, triangular in cross-section
and spindle-shaped, with a thin, papery, outer shell and small
black seeds.Guatemalais the biggest producer and exporter of
cardamom in the world, followed by India. Some other countries,
such asSri Lanka, have also begun to cultivate it.Elettariapods are
light green whileAmomumpods are larger and dark brown.It is the
world's third most expensivespiceby weight, outstripped in market
value only bysaffronandvanilla Etymology[edit]The word "cardamom"
is derived from theLatincardamomum, itself thelatinisationof
theGreek(kardamomon), a compound of(kardamon), "cress" +(amomon),
which was the name for a kind of an Indian spice plant. The
earliest attested form of the word is theMycenaean
Greekka-da-mi-ja, written inLinear Bsyllabic script, in the list of
flavourings on the "Spice" tablets found among palace archives in
the House of the Sphinxes inMycenae.
In theNew Testament(which was largely written in Greek), the
nameamomon[] appears in reference to an aromatic plant. This could
be derived - and some books state so - from the adjective amomos []
"blameless, without reproach"; given, however, that amomos is a
regional and poetic form, this may be less probable than (what
other books state) the derivation from Aramaic hemama, which was
not able to be verified.The modern genus nameElettariais derived
from the local name in a South Asian tongue; cf. Hindi ilaychi and
Punjabi ilaichi "green cardamom". The common source is Sanskrit,
where cardamom is called ela or ellka which is itself a loan from a
Dravidian language. From the corresponding Dravidian root, L, all
modern names of cardamom in the major Dravidian languages are
directly derived, e.g., Kannada elakki [], Telugu yelakulu, Tamil
elakkai and Malayalam elakkay The second element kai means
"vegetable".
Types and distribution
Green and black cardamomThe two main genera of the ginger family
named as forms of cardamom are distributed as
follows:Elettaria(commonly called cardamom, green cardamom, or true
cardamom) is distributed from India to Malaysia.Amomum(commonly
known asblack cardamom, brown cardamom,kravan, Java cardamom,
Bengal cardamom, Siamese cardamom, white cardamom, or red cardamom)
is distributed mainly inAsiaand Australia.The two types of
cardamom, and , were distinguished in the fourth century BCE by the
Greek father of botany,Theophrastus. Some of his informants told
him that these varieties came to Greece from the land of theMedesin
northern Persia, while others were aware it came originally from
India.
Ecology Elettaria cardamomumis used as a food plant by
thelarvaeof themothEndoclita hosei. Varieties
Cardamom plant
There were initially three natural varieties of green cardamom
plants.Malabar (Nadan/Native), as the name suggests, is the native
variety ofKerala. These plants havepanicleswhich grow horizontally
along the ground.Mysore, as the name suggests, is a native variety
ofKarnataka. These plants have panicles which grow vertically
upwards. The mysore variety has however declined in the past few
decades owing to the emergence of the more resistant and better
yielding "Green Gold" variety, and which is most commonly form of
cardamom harvested in Kerala.Vazhuka is a naturally occurring
hybrid between Malabar and Mysore varieties, and the panicles grow
neither vertically nor horizontally, but in between.Recently, a few
planters isolated high-yielding plants and started multiplying them
on a large scale. The most popular high-yielding variety is
'Njallani'. 'Njallani, also known asrup-ree-t, is a unique
high-yielding cardamom variety developed by an Indian farmer,
Sebastian Joseph, atKattappanain the South Indian state ofKerala.
K. J. Baby ofIdukki district, Kerala, has developed a purely white
flowered variety of Vazhuka type green cardamom having higher yield
than Njallani. The variety has high adaptability to different shade
conditions and can also be grown in waterlogged areas. Uses
Both forms of cardamom are used as flavorings in both food and
drink, as cooking spices and as a medicine.E. cardamomum(green
cardamom) is used as a spice, a masticatory, and in medicine; it is
also smoked sometimes.
Food and drink
Spice shop in Sri LankaCardamom has a strong, unique taste, with
an intensely aromatic, resinous fragrance. Black cardamom has a
distinctly more smokey, though not bitter, aroma, with a coolness
some consider similar to mint.Green cardamom is one of the most
expensive spices by weight, but little is needed to impart flavor.
It is best stored in pod form because once the seeds are exposed or
ground, they quickly lose their flavor. However, high-quality
ground cardamom seed is often more readily (and cheaply) available
and is an acceptable substitute. Grinding the pods and seeds
together lowers both the quality and the price. For recipes
requiring whole cardamom pods, a generally accepted equivalent is
10 pods equals 1 teaspoons of ground cardamom.
It is a common ingredient in Indian cooking and is often used
inbakinginNordic countries, such as in the Finnish sweet
breadpullaor in the Scandinavian breadJulekake. In theMiddle East,
green cardamom powder is used as a spice for sweet dishes, as well
as traditional flavouring in coffee and tea. Cardamom pods are
ground together with coffee beans to produce a powdered mixture of
the two, which is boiled with water to make coffee. Cardamom is
used to some extent in savoury dishes. In some Middle Eastern
countries, coffee and cardamom are often ground in a wooden mortar,
amihbaj, and cooked together in a skillet, amehmas, over wood or
gas, to produce mixtures as much as 40% cardamom.In South Asia,
green cardamom is often used in traditionalIndian sweetsand
inmasala chai(spiced tea). Black cardamom is sometimes used ingaram
masalafor curries. It is occasionally used as a garnish in basmati
rice and other dishes. It is often referred to as fat cardamom due
to its size. Individual seeds are sometimes chewed and used in much
the same way as chewing gum. It is even used by confectionery
giantWrigley; its Eclipse Breeze Exotic Mint packaging indicates
that it contains "cardamom to neutralize the toughest breath
odors." It has been known to be used forginmaking and inherbal
teas.Traditional medicine.
Cardamom (Elettaria cardamomum) essential oil in clear glass
vial
Green cardamom is broadly used in South Asia to treat infections
in teeth andgums, to prevent and treat throat troubles, congestion
of the lungs and pulmonarytuberculosis, inflammation of eyelids and
alsodigestivedisorders. It also is used to break up kidney stones
and gall stones, and was reportedly used as anantidotefor both
snake and scorpionvenom.Amomumis used as a spice and as an
ingredient in traditional medicine in systems of thetraditional
Chinese medicineinChina, inAyurvedain India, Pakistan,
Japan,KoreaandVietnam. Species in the genusAmomumare also used in
traditionalIndian medicine. Among other species, varieties and
cultivars,Amomum villosumcultivated in China, Laos and Vietnam is
used in traditional Chinese medicine to treat stomach
issues,constipation,dysentery, and other digestion
problems.TsaokocardamomAmomum tsao-kois cultivated inYunnan, China
and northwest Vietnam, both for medicinal purposes and as a
spice.Main constituents:The content of essential oil in the seeds
is strongly dependent on storage conditions, but may be as high as
8%. In the oil were
found-terpineol45%,myrcene27%,limonene8%,menthone6%,-phellandrene3%,1,8-cineol2%,sabinene2%
andheptane2%. (Phytochemistry, 26, 207, 1987) Other sources report
1,8-cineol (20 to 50%),-terpenylacetate(30%), sabinene, limonene (2
to 14%) andborneol.In the seeds of round cardamom from Jawa (A.
kepulaga), the content of essential oil is lower (2 to 4%), and the
oil contains mainly 1,8 cineol (up to 70%) plus-pinene(16%);
furthermore,-pinene, -terpineol andhumulenewere found.World
production[edit]Guatemala is the largest producer of cardamom in
the world, with an average annual yield of between 25,000 to 29,000
metric tons. India is the second producer worldwide (formerly the
largest ), generating approximately 15,000 metric tons annually.
Cardamom was first introduced to Guatemala in 1914. Increased
demand since the 1980s, principally from China, for bothAmomum
villosumandAmomum tsao-kohas provided a key source of income for
poor farmers living at higher altitudes in localized areas of
China, Laos and Vietnam, people typically isolated from many other
markets.Nepalwas previously the world's largest producer of large
cardamom. According to estimates of theAsociacin de Cardamomeros de
Guatemala (Cardegua) the harvest of 2012 will reach to about 29,000
metric tons, 12 percent more than in 2011 when they were 26,000
metric tons.
Gallery
Cardamom flower
Cardamom fruit and seeds
Green cardamom pods and seeds
Jar of green cardamom
White cardamom pods in a bowl
Cardamom pods as used as a spice in India
OBJECTIVES OF THE STUDY
Objective of the study is to prove that the production planning
and control practices has impact on the efficient utilization of
the resources, waste reduction, reduce waiting time and processing,
thus contributing to the profitability of the industry. On these
premise the study accentuated to address questions in order to
achieve the following objectives:(1)To know how the production
planning contributes to the efficient use of facilities and
equipments.
(2)To know the effects of Production Planning and Control on
Production function.
(3)To know whether production planning and control practices
lead to waste reduction and increased profit.
(4)To prove that short term production planning and scheduling
techniques employed by industries, is necessary in minimizing
process and customer waiting time.
PRODUCTION FUNCTION
After taking decisions about the type of business, its location,
layout etc. the entrepreneur steps into the shoe of production
manager and attempts to apply managerial principles to the
production function in an enterprise. 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. Production
management involves the managerial decisions regarding design of
the product and design of the production system i.e. determination
of production processes and production planning and control.
PRODUCTION PLANNING AND CONTROL
Once the entrepreneur has taken the decisions regarding the
product design and production processes and system, his next task
is to take steps for production planning and control, as this
function is essentially required for efficient and economical
production.Planned Production is the ability to look ahead,
organize and coordinate and having plenty of driving force and
capacity to lead and ability to supervise and coordinate work and
simulates his associates by means of a program of human relation
and organization of employees.
Production Planning and Control involve generally the
organization and planning of manufacturing process. Especially it
consists of the planning of routing, scheduling, dispatching
inspection, and coordination, control of materials, methods
machines, tools and operating times. The ultimate objective is the
organization of the supply and movement of materials and labour,
machines utilization and related activities, in order to bring
about the desired manufacturing results in terms of quality,
quantity, time and place.
Production planning without production control is like a bank
without a bank manager, planning initiates action while control is
an adjusting process, providing corrective measures for planned
development. Production control regulates and stimulates the
orderly how of materials in the manufacturing process from the
beginning to the end.
STEPS IN PPC (PRODUCTION PLANNING AND CONTROL)
Production Planning and Control (PPC) is a process that
comprises the performance of some critical; functions on either
side, viz., planning as well as control
Production planning
Production planning may be defined as the technique of
foreseeing every step in a long series of separate operations, each
step to be taken at the right time and in the right place and each
operation to be performed in maximum efficiency. It helps
entrepreneur to work out the quantity of material manpower, machine
and money requires for producing predetermined level of output in
given period of time.
Routing
Under this, the operations, their path and sequence are
established. To perform these operations the proper class of
machines and personnel required are also worked out. The main aim
of routing is to determine the best and cheapest sequence of
operations and to ensure that this sequence is strictly followed.
In small enterprises, this job is usually done by entrepreneur
himself in a rather adhoc manner. Routing procedure involves
following different activities.
(1) An analysis of the article to determine what to make and
what to buy.(2) To determine the quality and type of material(3)
Determining the manufacturing operations and their sequence.(4) A
determination of lot sizes(5) Determination of scrap factors(6) An
analysis of cost of the article(7) Organization of production
control forms.
Scheduling
It means working out of time that should be required to perform
each operation and also the time necessary to perform the entire
series as routed, making allowances for all factors concerned. It
mainly concerns with time element and priorities of a job. The
pattern of scheduling differs from one job to another which is
explained as below:
Production schedule
The main aim is to schedule that amount of work which can easily
be handled by plant and equipment without interference. Its not
independent decision as it takes into account following
factors.
(1) Physical plant facilities of the type required to process
the material being scheduled.(2) Personnel who possess the desired
skills and experience to operate the equipment and perform the type
of work involved.(3) Necessary materials and purchased parts.
Master Schedule
Scheduling usually starts with preparation of master schedule
which is weekly or monthly break-down of the production requirement
for each product for a definite time period, by having this as a
running record of total production requirements the entrepreneur is
in better position to shift the production from one product to
another as per the changed production requirements. This forms a
base for all subsequent scheduling acclivities. A master schedule
is followed by operator schedule which fixes total time required to
do a piece of work with a given machine or which shows the time
required to do each detailed operation of a given job with a given
machine or process.Manufacturing schedule: It is prepared on the
basis of type of manufacturing process involved. It is very useful
where single or few products are manufactured repeatedly at regular
intervals. Thus it would show the required quality of each product
and sequence in which the same to be operated.
Scheduling of Job to order manufacturing
Scheduling acquires greater importance in job to order
manufacturing. This will enable the speedy execution of job at each
center point.As far as small scale industry is concerned scheduling
is of utmost importance as it brings out efficiency in the
operations and s reduces cost price. The small entrepreneur should
maintain four types of schedules to have a close scrutiny of all
stages namely an enquiry schedule, a production schedule, a shop
schedule and an arrears schedule out of above four, a shop schedule
is the most important most suited to the needs of small scale
industry as it enables a foreman to see at a glance.
1. The total load on any section2. The operational sequence3.
The stage, which any job has reached.
Loading
The next step is the execution of the schedule plan as per the
route chalked out it includes the assignment of the work to the
operators at their machines or work places. So loading determines
who will do the work as routing determines where and scheduling
determines when it shall be done. Gantt Charts are most commonly
used in small industries in order to determine the existing load
and also to foresee how fast a job can be done. The usefulness of
their technique lies in the fact that they compare what has been
done and what ought to have been done.Most of a small scale
enterprise fails due to non-adherence to delivery schedules
therefore they can be successful if they have ability to meet
delivery order in time which no doubt depends upon production of
quality goods in right time. It makes all the more important for
entrepreneur to judge ahead of time what should be done, where and
when thus to leave nothing to chance once the work has begun.
Production control
Production control is the process of planning production in
advance of operations, establishing the extract route of each
individual item part\ or assembly, setting, starting and finishing
for each important item, assembly or the finishing production and
releasing the necessary orders as well as initiating the necessary
follow-up to have the smooth function of the enterprise. The
production control is of complicated nature in small industries.
The production planning and control department can function at its
best in small scale unit only when the work manager, the purchase
manager, the personnel manager and the financial controller assist
in planning production activities. The production controller
directly reports to the works manager but in small scale unit, all
the three functions namely material control, planning and control
are often performed by the entrepreneur himself production control
starts with dispatching and ends up with corrective actions.
Dispatching
Dispatching involves issue of production orders for starting the
operations. Necessary authority and conformation is given for:
1. Movement of materials to different workstations.2. Movement
of tools and fixtures necessary for each operation.3. Beginning of
work on each operation.4. Recording of time and cost involved in
each operation.5. Movement of work from one operation to another in
accordance with the route sheet.6. Inspecting or supervision of
work
Dispatching is an important step as it translates production
plans into production.
Follow up
Every production program involves determination of the progress
of work, removing bottlenecks in the flow of work and ensuring that
the productive operations are taking place in accordance with the
plans. It spots delays or deviations from the production plans. It
helps to reveal detects in routing and scheduling, misunderstanding
of orders and instruction, under loading or overloading of work
etc. All problems or deviations are investigated and remedial
measure are undertaken to ensure the completion of work by the
planned date.Inspection: This is mainly to ensure the quality of
goods. It can be required as effective agency of production
control.Corrective measures: Corrective action may involve any of
those activities of adjusting the route, rescheduling of work
changing the workloads, repairs and maintenance of machinery or
equipment, control over inventories of the cause of deviation is
the poor performance of the employees. Certain personnel decisions
like training, transfer, demotion etc. may have to be taken.
Alternate methods may be suggested to handle peak loads.
Inspection
This is mainly to ensure the quality of goods. It can be
required as effective agency of production control.
Corrective measures
Corrective action may involve any of those activities of
adjusting the route, rescheduling of work changing the workloads,
repairs and maintenance of machinery or equipment, control over
inventories of the cause of deviation is the poor performance of
the employees. Certain personnel decisions like training, transfer,
demotion etc. may have to be taken. Alternate methods may be
suggested to handle peak loads.
Problems with Traditional Production Planning and Control
There are many problems that occur during the cycle of
activities in the traditional approach to production planning and
control. Many of these problems result directly from the inability
of the traditional approach to deal with the complex and
ever-changing nature of manufacturing. The types of problems
commonly encountered in the planning and control of production are
the following:
1. Plant capacity problems
Production falls behind schedule due to a lack of labor and
equipment. This results in excessive overtime, delays in meeting
delivery schedules, customer complaints, backordering, and other
similar problems.
2. Suboptimal production scheduling
The wrong jobs are scheduled because of a lack of clear order
priorities, inefficient scheduling rules, and the ever-changing
status of jobs in the shop. As a consequence, production runs are
interrupted by jobs whose priorities have suddenly increased,
machine setups are increased, and jobs that are on schedule fall
behind. 3. Long manufacturing lead times
In an attempt to compensate for problems 1 and 2, production
planners allow extra time to produce an order. The shop becomes
overloaded, order priorities become confused, and the result is
excessively long manufacturing lead times. 4. Inefficient inventory
control
At the same time that total inventories are too high for raw
materials, work-in-progress, and finished products, there are stock
outs that occur on individual items needed for production. High
total inventories mean high carrying costs, while raw material
stock outs mean delays in meeting production schedules.5. Low work
centre utilizationThis problem results in part from poor scheduling
(excessive product changeovers and job interruptions), and from
other factors over which plant management has limited control
(e.g., equipment breakdowns, strikes, reduced demand for
products).
6. Process planning not followedThis is the situation in which
the regular planned routing is superseded by an ad hoc process
sequence. It occurs, for instance, because of bottlenecks at work
centers in the planned sequence. The consequences are longer
setups, improper tooling, and less efficient processes. 7. Errors
in engineering and manufacturing records Bills of materials are not
current, route sheets are not up to date with respect to the latest
engineering changes, inventory records are inaccurate, and
production piece counts are incorrect.
8. Quality problemsQuality defects are encountered in
manufactured components and assembled products, resulting in rework
or scrapped parts, thus causing delays in the shipping
schedule.
PRODUCTION PLANNING AND CONTROL AT R.L.MASAALA
Production plan is crucial to the success of any producing unit;
it is an activity which is continues in nature and required to be
revised time to time as per the requirements. It cant be done in
isolation by a particular department; rather it is an integrated
activity done by Planning and Control Department in collaboration
with Material Department, Production Department, and Quality
Control Department.
RESEARCH METHODOLOGY
Research methodology is a science of studying how research is
done scientifically. It is a way to systematically solve the
research problem by logically adopting various steps. Methodology
helps to understand not only the products of scientific inquiry but
the process itself. It also aims to describe and analyze methods,
throw light on their limitations and resources and clarify the
consequences, relating their potentialities to the twilight zone at
the frontiers of knowledge.In the making of this project I adopted
the following methodology:
PRIMARY DATACollection of data through questionnaireCollection
of data through interview with the employees.Collection of data
through factory visit.
SECONDARY DATAData collection through the industrys website.Data
collection through books.
SAMPLING
Sample size 15
INTERPRETATION OF DATA
Q1. Which is the first step in a manufacturing planning and
control system?
Production planningAchieving the forecastMaintaining the
required inventory levelMaintaining the planned block log
OptionsABCD
Response6711
Interpretation
On the basis of 15 respondent 46% respondent said that the first
step of manufacturing should be forecasting and 40 % of the
respondent give their response in favour of production
planning.
Q2. Do you think production planning and control is central to
the success of any Manufacturing unit?
Yes No
OptionsYesNo
Response150
Interpretation
All the 100% respondents believe that production planning and
control is central to the success of any manufacturing unit.
Production planning and control gives direction to the best use of
capacity with optimum utilization of production line, resources,
and other equipments. It helps in waste reduction and leads to
increased profitability.
Q3. What are the main objectives of Production Planning?a.
Optimum utilization of capacityb. Inventory controlc. Economy in
production timed. Ensure qualitye. Waste reduction and increased
profit
OptionsABcdE
Response43215
Interpretation
All the respondents believe that waste reduction and increased
profit is the main objective of production planning, some of them
also believe that optimum utilization of capacity is another
objective of production planning.
The other objective of production planning is inventory control,
economy in production time, and quality insurance.
Q4. Capacity planning contributes to the efficient use of
facilities and equipments?
YesNo
OptionsYesNo
Response123
Interpretation
Most of the respondents i.e. 80% are in favor of the statement
that capacity Planning contributes to the efficient use of facility
and equipments.
Proper Capacity planning leads to optimum utilization of
capacity reduces idle time, under or over utilization of
capacity.
Q5. Production Planning and Control makes the supervisor
ineffective?Yes No
OptionsYesNo
Response312
Interpretation
80% of respondents are against this statement because supervisor
makes the production planning and control effective with the use of
various methods of PPC.
Q6. The causes of inability to meet delivery date originally
promised due to :-
a) Lack of availability of material in time
b) Lack of availability of supervisor in timec) Lack of staffing
shift
d) Load balancing not done properly
OptionsABCD
Response6342
InterpretationThe causes of inability to meet delivery date
originally promised were not fulfilled mainly because lack of
availability of materials in time and lack of staffing shift.Load
balancing and supervisors not presence also may effect to meet the
delivery date.
Q7. On what basis do you plan your production?
a. Customer needsb. Target of marketing departmentc. Resources
availabled. Others
OptionsABCD
Response8340
Interpretation
According to the data collected from the respondents the
production planning of R.L.MASAALA is based on customer need i.e.
dealers demand for particular product.
The marketing department reports to the PPC/Store about dealers
requirements. PPC/Store communicates with the material department
about availability of material. Hence, market demand and
availability of resources is considered as base for production
plans.
Q8. If results are not according to the plans, what control
measures are taken?a. Revision of planb. Any other measures
OptionsAB
Response132
Interpretation
If the results are good there is no need to change any plan in
their production policy. If revision of the plan takes lot of time
then we should go for other measures also. At present people of
R.L.MASAALA do not have any other solution except revision of plan
to control deviations in plans and results.
Q9. Being capable to adjust their production facilities shortly
just after change in demand for products and without incurring
heavy expenses, greater flexibility in production is provided
by:-
a) Continuous productionb) Job and batch productionOptionsAB
Response411
InterpretationGreater flexibility in production is provided by
job and batch production because in it the production has been done
in lots on the basis of the order taken so the maintenance cost of
inventory is very less and it leads to the effective way of
production.
Q10. Do you feel or experienced hung up and bottlenecks in
implementing Production Plans.YesNoOptionsYesNo
Response123
Interpretation
80% of the respondents realize that they feel various
difficulties while implementing production plans.
FINDINGS
The PPC department of R.L. MASAALA believes in making plans and
decisions in cooperation with production department, marketing
department, material department, and quality control department. So
that a feasible plan can be made, executed properly, and optimum
results can be achieved. Hence, production planning and control is
an integrated activity and cant be done in isolation by any
particular department.
Following are the findings of this project about production
planning and control activities of R.L. MASAALA:
1. Production Planning is an integrated activity and cannot be
done in isolation by a particular department.2. PPC helps in
scheduling tasks and production runs and ensures production
capacity does not remain idle.3. The work should not be piled up
but should be done when it arises.4. Proper PPC helps to resort to
just- in- time systems and thereby reduce the overall inventory. It
enables to ensure that the right supplies are available at the
right time.5. PPC helps to reduce the cycle time and increase the
turnover via proper scheduling.6. PPC provide for adherence to the
quality standards so that quality of output is ensured.
To sum up we may say that PPC is of immense value to the
entrepreneur in capacity utilization and inventory control. More
importantly it improves his response time and quality. As such
effective PPC contributes to time, quality and cost parameters of
entrepreneurial success.
CONCLUSION
After doing this project I am in a position to conclude that
R.L. MASAALA has well defined and structured production planning
system. PPC defines the sequences and schedules of operations;
hence production planning contributes to the efficient use of
facilities and equipments.Production Planning and Control is done
to identify production process which leads to reduced lead time;
hence customer waiting time is also reduced. Production Planning
and Control ensures optimum utilization of production capacity,
material, and other equipments; hence it leads to waste reduction
and increased profits.Proper PPC helps to resort to just- in- time
systems and thereby reduce the overall inventory. It enables to
ensure that the right supplies are available at the right time.
Production Planning and Control helps to reduce the cycle time and
increase the turnover via proper scheduling. Production Planning
and Control provide for adherence to the quality standards so that
quality of output is ensured.Sufficient safety stock must be
maintained to meet unforeseen hindrances in the production process.
The industry should be providing time to time reminders to the
farmers and vendors so that they are aware about their
responsibilities which would reduce the lead time.The industry
could also involve third party logistics for their procurement and
distribution processes from farther areas to reduce time gap and
cost.
RECOMMENDATIONS
The production planning and control of R.L. MASAALA, highly
depends on the material availability. In case of shortage of
material the overall plan get disturbed. If such problem prevails
the optimum results cannot be achieved. To avoid such problem
following measures can be taken:
a. Proper Materials Planning should be done.b. R.L. MASAALA
purchases materials directly from the farmers, but at the time of
an emergency they should be in contact with some vendors.c.
Sufficient safety stock must be maintained to meet unforeseen
hindrances in the production process.d. The industry should be
providing time to time reminders to the farmers and vendors so that
they are aware about their responsibilities which would reduce the
lead time.e. The industry could also involve third party logistics
for their procurement and distribution processes from farther areas
to reduce time gap and cost.f. The industry can also involve
themselves in expansion process as there is an opportunity for
growth in this sector.g. As there is not much awareness about R.L.
MASAALA, the company should undertake marketing and promotional
programs.
BIBLIOGRAPHY
INTERNET
BOOKS Stephen N. Chapman The fundamentals of production planning
and control (First Edition) Year of Publication 2005, Pearson
Education India, pg no. (7-22), (60-88),(146-170,)(189-216) S. N.
CHARY Production and Operations Management (Second Edition) Year of
Publication 2000,Tata Mc graw- Hill Publishing Company Limited,
page no-(1-8),(136-140),(181-186),( 247-253) S.A. Chunawalla and
D.R. PATEL Production and Operation Management (Seventh Edition)
Year of Publication 2008, Himalaya Publishing House, pg no.
(1-15),(22-34),(125-143),(147-166),(220-337) P. Rama Murthy
Production and Operation Management (Second Edition) Year of
Publication 2005, New Age International Publishers, pg no.
(2-11),(19-26),(44-70),(97-136),(213-243),(332-366) R.
Panneerselvam Production And Operations Management (Third Edition)
Year of Publication 2012, PHI Learning Private Limited, pg no.
(16-27), (54-89), (132-177), (243-267)
ANNEXURE
Q1. Which is the first step in a manufacturing planning and
control system?a) Production planningb) Achieving the forecastc)
Maintaining the required inventory leveld) Maintaining the planned
block log
Q2. Do you think production planning and control is central to
the success of any Manufacturing unit?a) Yesb) No
Q3. What are the main objectives of Production Planning?a)
Optimum utilization of capacityb) Inventory controlc) Economy in
production timed) Ensure qualitye) Waste reduction and increased
profit
Q4. Capacity planning contributes to the efficient use of
facilities and equipments?a) Yesb) No
Q5. Production Planning and Control makes the supervisor
ineffectivea) Yes b) No
Q6. The causes of inability to meet delivery date originally
promised due to :-
a) Lack of availability of material in time
b) Lack of availability of supervisor in timec) Lack of staffing
shiftd) Load balancing not done properly
Q7. On what basis do you plan your production?
a) Customer needsb) Target of marketing departmentc) Resources
availabled) Others
Q8. If results are not according to the plans, what control
measures are taken?
a) Revision of planb) Any other measures
Q9. Being capable to adjust their production facilities shortly
just after change in demand for products and without incurring
heavy expenses, greater flexibility in production is provided
by:-
a) Continuous productionb) Job and batch production
Q10. Do you feel or experienced hung up and bottlenecks in
implementing Production Plans?
a) Yesb) No