PRODUCTION PLANNING AND CONTROL BY M. PRIYANKA M. PHARMACY SCHOOL OF PHARMACEUTICAL SCIENCES JNTUK
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PRODUCTION PLANNING AND CONTROL
BY
M. PRIYANKA
M. PHARMACY
SCHOOL OF PHARMACEUTICAL SCIENCES
JNTUK
CONTENTS
Introduction
Production planning
Process planning
Routing
Scheduling
loading
Production control
Dispatching
Follow up
Cost control
Quality control [email protected]
2
DEFINITIONS
PRODUCTION:-
Transformation of raw materials to finished goods
PRODUCTION MANAGEMENT:-
Application of management principles to the process of production in an industry
to produce desired goods in economical manner by co-ordinating the efforts of
men, material & machine.
4
PRODUCTION PLANNING:-
It is a technique which helps in planning & scheduling the work in the
manufacturing plant to obtain the desired quality of products with optimum
efficiency & at minimum cost.
PRODUCTION CONTROL:-
It ensures that the work is being done according to the plan
5
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’sMoney
Methods
Men
Machine
Material
6
A. PROCESS PLANNING
Process planning can be defined as the preparation of detailed plans for the
process required to manufacture a product as each manufacturing process
consists of numerous operations.
PROCESS PLANNING REQUIRES
Quantity of work to be done
Product specifications
Sequence of operations to be performed
Time required for each operation
Availability of manufacturing [email protected]
8
STEPS INVOLVED IN PROCESS PLANNING
Process selection
Selection of raw
material
Selection of
machinery parts
Process layout
Time setup &
standard operation
time
Documentation
9
a) PROCESS SELECTION:-
The operations selected for a particular process should be most economical
Should satisfy the product specifications
Selection mainly depends upon quality, quantity, time period & machines
available
b) SELECTION OF RAW MATERIALS:-
Should meet quality standards
Should show chemical compatibility
10
c) SELECTION OF MACHINERY PARTS:-
Proper selection of machinery attachments like inspection gauges, jigs, etc., is
necessary for the smooth functioning of machines. This helps in reducing the costs
& duration of production & results in high output.
d) PROCESS LAYOUT:-
It describes every step of operation as well as the sequence in which each
operation is to be carried out.
11
e) TIME SETUP & STANDARD OPERATION TIME:-
They should be established to complete the production within the time.
f) DOCUMENTATION:-
Process planning should be clearly summarized in documents such as
operation & route sheets.
12
B. ROUTING
Routing is the process of determining the sequence of operations to be carried out.
Determines the path for flow of work right from the selection of raw materials until
the completion of production of finished goods.
Routing is summarized in route sheets. Prepared sheets are then dispatched to the
production department.
Route sheets summarizes processes like
Description of operations
Sequence of operations
Type of machinery
Setup time
Operation [email protected]
13
C. SCHEDULING:-
Scheduling concerns with time element. It refers to the time frame of all production
activities therefore scheduling is also known as time phase of loading.
OBJECTIVE:-
To reduce the time of production
To ensure that the products can be delivered before the due date
TECHNIQUES:-
Master schedule
Perpetual schedule
Order schedule
14
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
15
Master schedule chart
MASTER SCHEDULE FOR TABLET PRODUCTION DEPARTMENT
Maximum production:---hours
Minimum production:----hours
Week1 Week 2 Week 3 Week 4
16
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
Order numberLoad in hours or days
Section P Section Q Section R
A
B
C
15
10
20
10
15
12
10
08
17
PREPARATION OF GANTT LOAD CHART
GANTT LOAD CHART
WEEK 1 WEEK 2 WEEK 3 WEEK 4
Section P
Section Q
Section R
By knowing the weekly capacity of each section, the load against each section for a
certain number of weeks can be calculated and plotted on a Gantt Load Chart.
18
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
19
ORDER SCHEDULE CHART
ORDER SCHEDULE CHART
AUGUST
1 2 3 4 5 6 7 8 9
Facility P
Facility Q
Facility R
20
D. LOADING
Loading is the relationship between load and capacity at work
place. It gives the information about number of machines, available,
their speed, capacity, capability. It helps to determine work load
and actual capacity of production.
21
PRODUCTION CONTROL
Production control is the comparison between planning output
and output achieved.
STEPS INVOLVED IN PRODUCTION CONTROL:-
Dispatching Follow upCost
controlQuality control
22
A. DISPATCHING
It is the process of issuing orders & instructions to a particular operating
section of industry to start the processing of a given job on an assigned
machine in accordance with the previously planned sequence & time as
detailed in route sheets & schedule charts.
Movement of materials to different work stations, movement of work from
one operation to another & supervision of work comes under this category.
23
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
24
C. COST CONTROL
The total cost for the production of goods is determined & is compared with
standard cost to calculate the deviations as well as to follow corrective
action.
It can be controlled by
Reducing wastage
Value analysis
Inventory control
25
D. QUALITY CONTROL
It helps to avoid & detects the defects in production process & isolation of
defective finished goods
Finished products are inspected to ensure their acceptable quality
Quality control techniques
Statistical quality control
Probability concept
Poisson distribution
Sampling inspection
26
REFERENCES
www.wikipedia.com
www.managementstudyguide.com
www.tandfonline.com
27
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