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MODULE 1: INTRODUCTION TO PRODUCTION MANAGEMENT

Organizations are designed mainly to produce products or services. If these organizations

must survive and grow, the operations function must be undertaken in the most economical
manner possible. As most companies are expected to make profits, any activity, including those for
operations must be managed to contribute to the accomplishment of such objectives. Production 
concern itself with creation of all goods and services, be they diverse item as cars, piece of
furniture and laundry facilities.

1.1. DEFINITION OF PRODUCTION MANAGEMENT

 A function of management, related to planning, coordinating and controlling the

resources required for production to produce specified product by specified methods, by
optimal utilization of resources.
 A management function which plans, organizes, coordinates, directs and controls the
material supply and processing activities of an enterprise, so that specified products are
produced by specified methods to meet an approved sales program. These activities are
being carried out in such a manner that labor, plant and capital available are used to the
best advantage of the organization.
 It deals with planning, control, and decision making necessary for carrying out the
production process.
 The design, operation, and improvement of the systems that create and deliver the
firm’s primary products and services.

Production/operations management is the process, which combines and transforms

various resources used in the production/operations subsystem of the organization into value
added product/services in a controlled manner as per the policies of the organization.
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Therefore, it is that part of an organization, which is concerned with the transformation

of a range of inputs into the required (products/services) having the requisite quality level.

The set of interrelated management activities, which are involved in manufacturing certain
products, is called as production management. If the same concept is extended to services
management, then the corresponding set of management activities is called as operations
management.

1.2. HISTORICAL EVOLUTION OF PRODUCTION AND OPERATIONS MANAGEMENT

For over two centuries operations and production management has been recognized as an
important factor in a country’s economic growth.

The traditional view of manufacturing management began in eighteenth century when

Adam Smith recognized the economic benefits of specialization of labor. He recommended
breaking of jobs down into subtasks and recognizes workers to specialized tasks in which they
would become highly skilled and efficient. In the early twentieth century, F.W. Taylor implemented
Smith’s theories and developed scientific management. From then till 1930, many techniques were
developed prevailing the traditional view. Brief information about the contributions to
manufacturing management is shown in the Table 1.1.
TABLE 1.1 Historical summary of operations management
Dat Contribution Contributor
e
177 Specialization of labor in manufacturing Adam Smith
6
179 Interchangeable parts, cost accounting Eli Whitney and others
9
183 Division of labor by skill; assignment of jobs by
2 skill; basics of time study Charles Babbage
190 Scientific management time study and work study
0 developed; dividing planning and doing of work Frederick W. Taylor
190 Motion of study of jobs Frank B. Gilbreth
0
190 Scheduling techniques for employees, machines
1 jobs in manufacturing Henry L. Gantt
191 Economic lot sizes for inventory control F.W. Harris
5
192 Human relations; the Hawthorne studies Elton Mayo
7
193 Statistical inference applied to product quality:
1 quality control charts W.A. Shewart
193 Statistical sampling applied to quality control:
H.F. Dodge & H.G. Roming
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5 inspection sampling plans

194 Operations research applications in World War II P.M. Blacker & others
0
194 Digital computer John Mauchlly & J.P. Eckert
6
194 Linear programming G.B. Dantzig, Williams &
7 others
195 Mathematical programming, on-linear and A. Charnes, W.W. Cooper
0 stochastic Processes

195 Commercial digital computer: large-scale

1 computations available. Sperry Univac
196 Organizational behavior: continued study of
0 people at work L. Cummings, L. Porter
197 Integrating operations into overall strategy and W. Skinner J. Orlicky and
0 policy,
Computer applications to manufacturing, G. Wright
Scheduling and control, Material requirement
planning (MRP)
198 Quality and productivity applications from Japan: W.E. Deming and J. Juran
0 robotics CAD-CAM

Production management becomes the acceptable term from 1930s to 1950s. As F.W. Taylor’s
works become more widely known, managers developed techniques that focused on economic
efficiency in manufacturing. Workers were studied in great detail to eliminate wasteful efforts and
achieve greater efficiency. At the same time, psychologists, socialists and other social scientists
began to study people and human behavior in the working environment. In addition, economists,
mathematicians, and computer socialists contributed newer, more sophisticated analytical
approaches.

With the 1970s emerges two distinct changes in our views. The most obvious of these, reflected
in the new name operations management was a shift in the service and manufacturing sectors of
the economy. As service sector became more prominent, the change from ‘production’ to
‘operations’ emphasized the broadening of our field to service organizations. The second, more
suitable change was the beginning of an emphasis on synthesis, rather than just analysis, in
management practices.

1.3. CONCEPT OF PRODUCTION

Production function is that part of an organization, which is concerned with the

transformation of a range of inputs into the required outputs (products) having the requisite
quality level.
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Production is defined as “the step-by-step conversion of one form of material into another form
through chemical or mechanical process to create or enhance the utility of the product to the user.”
Thus production is a value addition process. At each stage of processing, there will be value
addition.

Edwood Buffa defines production as ‘a process by which goods and services are created’.

Some examples of production are: manufacturing custom-made products like, boilers with a
specific capacity, constructing flats, some structural fabrication works for selected customers, etc.,
and manufacturing standardized products like, car, bus, motor cycle, radio, television, etc.

1.4. OBJECTIVE OF PRODUCTION MANAGEMENT

The objective of Production Management is to:

 Produce the desired product or specified product by specified methods so that the
optimal utilization of available resources is met with.
 To produce goods that has marketability at the cheapest price by proper planning of the
manpower, material and processes.
 To deliver right goods of right quantity at right place and at right price.

When the above objective is achieved, we say that we have effective Production
Management system.
1. RIGHT QUALITY

The quality of product is established based upon the customers needs. The right quality is
not necessarily best quality. It is determined by the cost of the product and the technical
characteristics as suited to the specific requirements.

2. RIGHT QUANTITY

The manufacturing organization should produce the products in right number. If they are
produced in excess of demand the capital will block up in the form of inventory and if the quantity
is produced in short of demand, leads to shortage of products.

3. RIGHT TIME

Timeliness of delivery is one of the important parameter to judge the effectiveness

of production department. So, the production department has to make the optimal
utilization of input resources to achieve its objective.

4. RIGHT MANUFACTURING COST

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Manufacturing costs are established before the product is actually manufactured.

Hence, all attempts should be made to produce the products at pre-established cost, so as
to reduce the variation between actual and the standard (pre-established) cost.

1.5. MAIN COMPONENT OF PRODUCTION AND OPERATIONS MANAGEMENT

Effectiveness - Refers to goal achievement. Example: When one is able to reach his objectives,
say produce 10,000 units in one month, then, he is effective.

Efficiency - Is related to cost of doing something, or the resource utilization involved.

System - Provides an efficient and effective framework of activities necessary to attain an

objective.  It is dynamic arrangement of elements, each designed to interact with the other, and
thus it is more than just a static combinations.

Element - Consist of men, materials, machines, process and information network designed
and located to interact harmoniously.

1.6. PRODUCTION SYSTEM

The production system of an organization is that part, which produces products of an

organization. It is that activity whereby resources, flowing within a defined system, are
combined and transformed in a controlled manner to add value in accordance with the
policies communicated by management. A simplified production system is shown above.

The production system has the following characteristics:

1. Production is an organized activity, so every production system has an objective.

2. The system transforms the various inputs to useful outputs.
3. It does not operate in isolation from the other organization system.
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4. There exists a feedback about the activities, which is essential to control and improve system
performance.

1.7. CLASSIFICATION OF PRODUCTION SYSTEM

Production systems can be classified as Job Shop, Batch, Mass and Continuous Production
systems.

Job Shop Production

Job shop production are characterized by manufacturing of one or few quantity of products
designed and produced as per the specification of customers within prefixed time and cost. The
distinguishing feature of this is low volume and high variety of products.

A job shop comprises of general purpose machines arranged into different departments.
Each job demands unique technological requirements, demands processing on machines in a certain
sequence.

Characteristics

The Job-shop production system is followed when there is:

1. High variety of products and low volume.
2. Use of general purpose machines and facilities.
3. Highly skilled operators who can take up each job as a challenge because of uniqueness.
4. Large inventory of materials, tools, parts.
5. Detailed planning is essential for sequencing the requirements of each product, capacities for
each work center and order priorities.

Advantages

Following are the advantages of job shop production:

1. Because of general purpose machines and facilities variety of products can be produced.
2. Operators will become more skilled and competent, as each job gives them learning
opportunities.
3. Full potential of operators can be utilized.
4. Opportunity exists for creative methods and innovative ideas.
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Limitations

Following are the limitations of job shop production:

1. Higher cost due to frequent set up changes.
2. Higher level of inventory at all levels and hence higher inventory cost.
3. Production planning is complicated.
4. Larger space requirements.

Batch Production

Batch production is defined by American Production and Inventory Control Society

(APICS) “as a form of manufacturing in which the job passes through the functional departments
in lots or batches and each lot may have a different routing.” It is characterized by the manufacture
of limited number of products produced at regular intervals and stocked awaiting sales.

Characteristics

Batch production system is used under the following circumstances:

1. When there is shorter production runs.
2. When plant and machinery are flexible.
3. When plant and machinery set up is used for the production of item in a batch and change
of set up is required for processing the next batch.
4. When manufacturing lead time and cost are lower as compared to job order production.

Advantages

Following are the advantages of batch production:

1. Better utilization of plant and machinery.
2. Promotes functional specialization.
3. Cost per unit is lower as compared to job order production.
4. Lower investment in plant and machinery.
5. Flexibility to accommodate and process number of products.
6. Job satisfaction exists for operators.

Limitations

Following are the limitations of batch production:

1. Material handling is complex because of irregular and longer flows.
2. Production planning and control is complex.
3. Work in process inventory is higher compared to continuous production.
4. Higher set up costs due to frequent changes in set up.

Mass Production
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Manufacture of discrete parts or assemblies using a continuous process are called mass
production. This production system is justified by very large volume of production. The machines
are arranged in a line or product layout. Product and process standardization exists and all outputs
follow the same path.

Characteristics

Mass production is used under the following circumstances:

1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production capacities and output rates.
3. Large volume of products.
4. Shorter cycle time of production.
5. Lower in process inventory.
6. Perfectly balanced production lines.
7. Flow of materials, components and parts is continuous and without any back tracking.
8. Production planning and control is easy.
9. Material handling can be completely automatic.

Advantages

Following are the advantages of mass production:

1. Higher rate of production with reduced cycle time.
2. Higher capacity utilization due to line balancing.
3. Less skilled operators are required.
4. Low process inventory.
5. Manufacturing cost per unit is low.

Limitations

Following are the limitations of mass production:

1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major change with the changes in the product design.
3. High investment in production facilities.
4. The cycle time is determined by the slowest operation.

Continuous Production

Production facilities are arranged as per the sequence of production operations from the first
operations to the finished product. The items are made to flow through the sequence of operations
through material handling devices such as conveyors, transfer devices, etc.

Characteristics

Continuous production is used under the following circumstances:

1. Dedicated plant and equipment with zero flexibility.
2. Material handling is fully automated.
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3. Process follows a predetermined sequence of operations.

4. Component materials cannot be readily identified with final product.
5. Planning and scheduling is a routine action.

Advantages

Following are the advantages of continuous production:

1. Standardization of product and process sequence.
2. Higher rate of production with reduced cycle time.
3. Higher capacity utilization due to line balancing.
4. Manpower is not required for material handling as it is completely automatic.
5. Person with limited skills can be used on the production line.
6. Unit cost is lower due to high volume of production.

Limitations

Following are the limitations of continuous production:

1. Flexibility to accommodate and process number of products does not exist.
2. Very high investment for setting flow lines.
3. Product differentiation is limited.

1.8 BENEFITS DERIVED FROM EFFICIENT PRODUCTION MANAGEMENT

The efficient Production Management will give benefits to the various sections of the society.
They are:

 Consumer benefits from improved industrial productivity, increased use value in the
product. Products are available to him at right place, at right price, at right time, in desired
quantity and of desired quality.

 Investors: They get increased security for their investments, adequate market returns,
and creditability and good image in the society

 Employee: They get adequate wages, job security, improved working conditions and
increased personal and job satisfaction.

 Suppliers: They will get confidence in management and their bills can be realized without
any delay.

 Community: Community enjoys benefits from economic and social stability.

 The Nation will achieve prospects and security because of increased productivity and
healthy industrial atmosphere.

1.9 FUNCTIONS OF PRODUCTION MANAGEMENT

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The functions of Production Management depend upon the size of the firm. In small firms
the production manager may have to look after production planning and control along with
personnel, marketing, finance and purchase functions. In medium sized firms, there may be
separate managers for Personnel, marketing and Finance functions. But the production “planning
& control” and “Purchase and stores” may be under the control of production management
department. In large sized firms the activities of Production Management is confined to the
management of production activities only. As such, there is no hard and fast rule or guidelines to
specify the function of production management, but in the academic interest we can mention
some of the functions, which are looked after by the Production Management department. They
are:

Materials

The selection of materials for the product. Production manager must have sound
knowledge of materials and their properties, so that he can select appropriate materials for his
product. In a dairy plant, basic raw material is milk, which is highly perishable in nature. So
special knowledge and care should be needed to transform in to various dairy products.

Methods

Finding the best method for the process, to search for the methods to suit the available
resources, identifying the sequence of process are some of the activities of Production
Management.

Machines and equipment

Selection of suitable machinery for the process desired, designing the maintenance policy
and design of layout of machines are taken care of by the production management department.

Estimating

To fix up the production targets and delivery dates and to keep the production costs at
minimum, production management department does a thorough estimation of production times
and production costs. In competitive situation this will help the management to decide what
should be done in arresting the costs at desired level.

Loading and scheduling

The production management department has to draw the time table for various
production activities, specifying when to start and when to finish the process required. It also has
to draw the timings of materials movement and plan the activities of manpower. The scheduling is
to be done keeping in mind the loads on hand and capacities of facilities available.

Routing
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This is the most important function of production management department. The Routing
consists of fixing the flow lines for various raw materials, components etc., from the stores to the
packing of finished product, so that all concerned know what exactly is happening on the shop
floor.

Dispatching

The Production Management department has to prepare various documents such as Job
Cards, Route sheets, Move Cards, Inspection Cards for each and every component of the product.
These are prepared in a set of five copies. These documents are to be released from Production
Management department to give green signal for starting the production. The activities of the
shop floor will follow the instructions given in these documents. Activity of releasing the document
is known as dispatching.

Expediting or follow up

Once the documents are dispatched, the management wants to know whether the
activities are being carried out as per the plans or not. Dairy Technologist go round the production
floor along with the plans, compare the actual with the plan and feedback the progress of the
work to the management. This will help the management to evaluate the plans.

Inspection

Here inspection is generally concerned with the inspection activities during production, but
a separate quality control department does the quality inspection, which is not under the control
of Production Management. This is true because, if the quality inspection is given to production
Management, then there is a chance of qualifying the defective products also.

Evaluation

The Production department must evaluate itself and its contribution in fulfilling the
corporate objectives and the departmental objectives. This is necessary for setting up the
standards for future. Whatever may be the size of the firm, production management department
alone must do routing, scheduling, loading, dispatching and expediting. This is because the
department knows very well regarding materials, methods, and available resources etc. If the firms
are small, all the above-mentioned functions are to be carried out by Production Management
Department. In medium sized firms in addition to routing, scheduling and loading, dispatching and
expediting, some more functions like methods, machines may be under the control of production
management department. In large firms, there will be separate departments for methods,
machines, materials and others but routing, loading and scheduling are the sole functions of
Production Management.

2.0 IMPORTANCE OF PRODUCTION MANAGEMENT

The importance of production management to the business firm:

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1. Accomplishment of firm's objectives: Production management helps the business firm to

achieve all its objectives. It produces products, which satisfy the customers' needs and wants.
So, the firm will increase its sales. This will help it to achieve its objectives.
2. Reputation, Goodwill and Image : Production management helps the firm to satisfy its
customers. This increases the firms reputation, goodwill and image. A good image helps the firm
to expand and grow.
3. Helps to introduce new products: Production management helps to introduce new
products in the market. It conducts Research and development (R&D). This helps the firm to
develop newer and better quality products. These products are successful in the market because
they give full satisfaction to the customers.
4. Supports other functional areas: Production management supports other functional areas
in an organization, such as marketing, finance, and personnel. The marketing department will
find it easier to sell good-quality products, and the finance department will get more funds due
to increase in sales. It will also get more loans and share capital for expansion and
modernization. The personnel department will be able to manage the human resources
effectively due to the better performance of the production department.
5. Helps to face competition : Production management helps the firm to face competition in
the market. This is because production management produces products of right quantity, right
quality, right price and at the right time. These products are delivered to the customers as per
their requirements.
6. Optimum utilization of resources : Production management facilitates optimum utilization
of resources such as manpower, machines, etc. So, the firm can meet its capacity utilization
objective. This will bring higher returns to the organization.
7. Minimizes cost of production: Production management helps to minimize the cost of
production. It tries to maximize the output and minimize the inputs. This helps the firm to
achieve its cost reduction and efficiency objective.
8. Expansion of the firm: The Production management helps the firm to expand and grow.
This is because it tries to improve quality and reduce costs. This helps the firm to earn higher
profits. These profits help the firm to expand and grow.

The importance of production management to customers and society:

1. Higher standard of living: Production management conducts continuous research and

development (R&D). So they produce new and better varieties of products. People use these
products and enjoy a higher standard of living.
2. Generates employment: Production activities create many different job opportunities in
the country, either directly or indirectly. Direct employment is generated in the production area,
and indirect employment is generated in the supporting areas such as marketing, finance,
customer support, etc.
3. Improves quality and reduces cost: Production management improves the quality of the
products because of research and development. Because of large-scale production, there are
economies of large scale. This brings down the cost of production. So, consumer prices also
reduce.
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4. Spread effect:  Because of production, other sectors also expand. Companies making spare
parts will expand. The service sector such as banking, transport, communication, insurance,
BPO, etc. also expand. This spread effect offers more job opportunities and boosts economy.
5. Creates utility: Production creates Form Utility. Consumers can get form utility in the
shape, size and designs of the product. Production also creates time utility, because goods are
available whenever consumers need it.
6. Boosts economy: Production management ensures optimum utilization of resources and
effective production of goods and services. This leads to speedy economic growth and well-
being of the nation.

MODULE 2: OPERATING SYSTEM

Operating system converts inputs in order to provide outputs which are required by a
customer. It converts physical resources into outputs, the function of which is to satisfy customer
wants i.e., to provide some utility for the customer. In some of the organization the product is a
physical good (hotels) while in others it is a service (hospitals). Bus and taxi services, tailors, hospital
and builders are the examples of an operating system.

Everett E. Adam & Ronald J. Ebert define operating system as, “An operating system (function)
of an organization is the part of an organization that produces the organization’s physical goods
and services.”

Ray Wild defines operating system as, “An operating system is a configuration of resources
combined for the provision of goods or services.”

2.1 CONCEPT OF OPERATIONS

An operation is defined in terms of the mission it serves for the organization, technology it
employs and the human and managerial processes it involves. Operations in an organization can
be categorized into manufacturing operations and service operations. Manufacturing operation is
a conversion process that includes manufacturing yields a tangible output: a product, whereas, a
conversion process that includes service yields an intangible output: a deed, a performance, an
effort.

2.2 DISTINCTION BETWEEN MANUFACTURING OPERATIONS AND SERVICE OPERATIONS

Following characteristics can be considered for distinguishing manufacturing operations

with service operations:

1. Tangible/Intangible nature of output

2. Consumption of output
3. Nature of work (job)
4. Degree of customer contact
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5. Customer participation in conversion

6. Measurement of performance

Manufacturing is characterized by tangible outputs (products), outputs that customers

consume overtime, jobs that use less labor and more equipment, little customer contact, no
customer participation in the conversion process (in production), and sophisticated methods for
measuring production activities and resource consumption as product are made.

Service is characterized by intangible outputs, outputs that customers consumes

immediately, jobs that use more labor and less equipment, direct consumer contact, frequent
customer participation in the conversion process, and elementary methods for measuring
conversion activities and resource consumption. Some services are equipment based namely rail-
road services, telephone services and some are people based namely tax consultant services, hair
styling.

2.3 OPERATIONS MANAGEMENT

A Framework for Managing Operations

Managing operations can be enclosed in a frame of general management function as

shown in Fig. 1.3. Operation managers are concerned with planning, organizing, and controlling
the activities which affect human behavior through models.

PLANNING

Activities that establishes a course of action and guide future decision-making is

planning. The operations manager defines the objectives for the operations subsystem of the
organization, and the policies, and procedures for achieving the objectives. This stage includes
clarifying the role and focus of operations in the organization’s overall strategy. It also involves
product planning, facility designing and using the conversion process.

ORGANIZING

Activities that establishes a structure of tasks and authority. Operation managers

establish a structure of roles and the flow of information within the operations subsystem. They
determine the activities required to achieve the goals and assign authority and responsibility for
carrying them out.

CONTROLLING

Activities that assure the actual performance in accordance with planned performance.
To ensure that the plans for the operations subsystems are accomplished, the operations manager
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must exercise control by measuring actual outputs and comparing them to planned operations
management. Controlling costs, quality, and schedules are the important functions here.

BEHAVIOR

Operation managers are concerned with how their efforts to plan, organize, and control
affect human behavior. They also want to know how the behavior of subordinates can affect
management’s planning, organizing, and controlling actions. Their interest lies in decision-making
behavior.

MODELS

As operation managers plan, organize, and control the conversion process, they encounter
many problems and must make many decisions. They can simplify their difficulties using models
like aggregate planning models for examining how best to use existing capacity in short-term,
break even analysis to identify break even volumes, linear programming and computer simulation
for capacity utilization, decision tree analysis for long-term capacity problem of facility expansion,
simple median model for determining best locations of facilities etc.

2.4 OBJECTIVES OF OPERATIONS MANAGEMENT

Objectives of operations management can be categorized into customer service and

resource utilization.
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CUSTOMER SERVICE

The first objective of operating systems is the customer service to the satisfaction of
customer wants. Therefore, customer service is a key objective of operations management. The
operating system must provide something to a specification which can satisfy the customer in terms
of cost and timing. Thus, primary objective can be satisfied by providing the ‘right thing at a right
price at the right time’.

These aspects of customer service—specification, cost and timing—are described for four
functions in Table 1.2. They are the principal sources of customer satisfaction and must, therefore,
be the principal dimension of the customer service objective for operations managers.

TABLE 1.2 Aspects of customer service

Principal Principal customer wants
function Primary considerations Other considerations
Manufacture Goods of a given, Cost, i.e., purchase price or cost of
requested or obtaining goods.
acceptable specification Timing, i.e., delivery delay from
order or request to receipt of
goods.
Transport Management of a given, Cost, i.e., cost of movements.
requested Timing, i.e.,
or acceptable specification 1. Duration or time to move.
2. Wait or delay from requesting to
its commencement.
Supply Goods of a given, Cost, i.e., purchase price or cost of
requested or obtaining goods.
acceptable specification Timing, i.e., delivery delay from
order or request to receipt of
goods.
Service Treatment of a given, Cost, i.e., cost of movements.
requested or
acceptable specification Timing, i.e.,
1. Duration or time required for
treatment.
2. Wait or delay from requesting
treatment to its commencement.

Generally an organization will aim reliably and consistently to achieve certain standards and
operations manager will be influential in attempting to achieve these standards. Hence, this
objective will influence the operations manager’s decisions to achieve the required customer
service.
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RESOURCE UTILIZATION

Another major objective of operating systems is to utilize resources for the satisfaction of
customer wants effectively, i.e., customer service must be provided with the achievement of
effective operations through efficient use of resources. Inefficient use of resources or inadequate
customer service leads to commercial failure of an operating system.

Operations management is concerned essentially with the utilization of resources, i.e.,

obtaining maximum effect from resources or minimizing their loss, under utilization or waste. The
extent of the utilization of the resources’ potential might be expressed in terms of the proportion
of available time used or occupied, space utilization, levels of activity, etc. Each measure indicates
the extent to which the potential or capacity of such resources is utilized. This is referred as the
objective of resource utilization.

Operations management is also concerned with the achievement of both satisfactory

customer service and resource utilization. An improvement in one will often give rise to
deterioration in the other. Often both cannot be maximized, and hence a satisfactory performance
must be achieved on both objectives. All the activities of operations management must be tackled
with these two objectives in mind, and many of the problems will be faced by operations
managers because of this conflict. Hence, operations managers must attempt to balance these
basic objectives.

Table 1.3 summarizes the twin objectives of operations management. The type of balance
established both between and within these basic objectives will be influenced by market
considerations, competitions, the strengths and weaknesses of the organization, etc. Hence, the
operations managers should make a contribution when these objectives are set.

TABLE 1.3 The twin objectives of operations management

The customer service objective. The resource utilization objective.

To provide agreed/adequate levels To achieve adequate levels of resource
of customer service (and hence customer utilization (or productivity) e.g., to
satisfaction) by providing goods or achieve agreed levels of utilization of
services with the right specification, at materials, machines and labor.
the right cost and at the right time.

2.5 MANAGING GLOBAL OPERATIONS

The term ‘globalization’ describes businesses’ deployment of facilities and operations

around the world. Globalization can be defined as a process in which geographic distance becomes
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a factor of diminishing importance in the establishment and maintenance of cross border

economic, political and socio-cultural relations. It can also be defined as worldwide drive toward a
globalized economic system dominated by supranational corporate trade and banking institutions
that are not accountable to democratic processes or national governments.

There are four developments, which have spurred the trend toward globalization. These
are:

1. Improved transportation and communication technologies;

2. Opened financial systems;
3. Increased demand for imports; and
4. Reduced import quotas and other trade barriers.

When a firm sets up facilities abroad it involve some added complexities in its operation.
Global markets impose new standards on quality and time. Managers should not think about
domestic markets first and then global markets later, rather it could be think globally and act
locally. Also, they must have a good understanding of their competitors. Some other important
challenges of managing multinational operations include other languages and customs, different
management style, unfamiliar laws and regulations, and different costs.

Managing global operations would focus on the following key issues:

1. To acquire and properly utilize the following concepts and those related to global
operations, supply chain, logistics, etc.
2. To associate global historical events to key drivers in global operations from different
perspectives.
3. To develop criteria for conceptualization and evaluation of different global operations.
4. To associate success and failure cases of global operations to political, social, economical
and technological environments.
5. To envision trends in global operations.
6. To develop an understanding of the world vision regardless of their country of origin,
residence or studies in a respectful way of perspectives of people from different races,
studies, preferences, religion, politic affiliation, place of origin, etc.

2.6 SCOPE OF PRODUCTION AND OPERATIONS MANAGEMENT

Production and operations management concern with the conversion of inputs into
outputs, using physical resources, so as to provide the desired utilities to the customer while
meeting the other organizational objectives of effectiveness, efficiency and adoptability. It
distinguishes itself from other functions such as personnel, marketing, finance, etc., by its primary
concern for ‘conversion by using physical resources.’ Following are the activities which are listed
under production and operations management functions:

1. Location of facilities
2. Plant layouts and material handling
 19

3. Product design
4. Process design
5. Production and planning control
6. Quality control
7. Materials management
8. Maintenance management

LOCATION OF FACILITIES

Location of facilities for operations is a long-term capacity decision which involves a long term
commitment about the geographically static factors that affect a business organization. It is an
important strategic level decision-making for an organization. It deals with the questions such as
‘where our main operations should be based?’

The selection of location is a key-decision as large investment is made in building plant and
machinery. An improper location of plant may lead to waste of all the investments made in plant
and machinery equipment. Hence, location of plant should be based on the company’s expansion
plan and policy, diversification plan for the products, changing sources of raw materials and many
other factors. The purpose of the location study is to find the optimal location that will results in
the greatest advantage to the organization.

PLANT LAYOUT AND MATERIAL HANDLING

Plant layout refers to the physical arrangement of facilities. It is the configuration of

departments, work centers and equipment in the conversion process. The overall objective of the
plant layout is to design a physical arrangement that meets the required output quality and
quantity most economically.

According to James Moore, “Plant layout is a plan of an optimum arrangement of facilities

including personnel, operating equipment, storage space, material handling equipment and all
other supporting services along with the design of best structure to contain all these facilities”.

‘Material Handling’ refers to the ‘moving of materials from the store room to the machine and
from one machine to the next during the process of manufacture’. It is also defined as the ‘art and
science of moving, packing and storing of products in any form’. It is a specialized activity for a
modern manufacturing concern, with 50 to 75% of the cost of production. This cost can be
reduced by proper section, operation and maintenance of material handling devices. Material
handling devices increases the output, improves quality, speeds up the deliveries and decreases
the cost of production. Hence, material handling is a prime consideration in the designing new
plant and several existing plants.

PRODUCT DESIGN
 20

Product design deals with conversion of ideas into reality. Every business organization have
to design, develop and introduce new products as a survival and growth strategy. Developing the
new products and launching them in the market is the biggest challenge faced by the
organizations. The entire process of need identification to physical manufactures of product
involves three functions: marketing, product development, manufacturing. Product development
translates the needs of customers given by marketing into technical specifications and designing
the various features into the product to these specifications. Manufacturing has the responsibility
of selecting the processes by which the product can be manufactured. Product design and
development provides link between marketing, customer needs and expectations and the
activities required to manufacture the product.

PROCESS DESIGN

Process design is a macroscopic decision-making of an overall process route for converting

the raw material into finished goods. These decisions encompass the selection of a process, choice
of technology, process flow analysis and layout of the facilities. Hence, the important decisions in
process design are to analyze the workflow for converting raw material into finished product and
to select the workstation for each included in the workflow.

PRODUCTION PLANNING AND CONTROL

Production planning and control can be defined as the process of planning the production
in advance, setting the exact route of each item, fixing the starting and finishing dates for each
item, to give production orders to shops and to follow up the progress of products according to
orders.

The principle of production planning and control lies in the statement ‘First Plan Your Work
and then Work on Your Plan’. Main functions of production planning and control includes
planning, routing, scheduling, dispatching and follow-up.

Planning is deciding in advance what to do, how to do it, when to do it and who is to do it.
Planning bridges the gap from where we are, to where we want to go. It makes it possible for
things to occur which would not otherwise happen.

Routing may be defined as the selection of path which each part of the product will follow,
which being transformed from raw material to finished products. Routing determines the most
advantageous path to be followed from department to department and machine to machine till
raw material gets its final shape.

Scheduling determines the program for the operations. Scheduling may be defined as ‘the
fixation of time and date for each operation’ as well as it determines the sequence of operations to
be followed.
 21

Fig. 1.4 Scope of production and operations management

Dispatching is concerned with the starting the processes. It gives necessary authority so as
to start a particular work, which has already been planned under ‘Routing’ and ‘Scheduling’.
Therefore, dispatching is ‘release of orders and instruction for the starting of production for any
item in acceptance with the route sheet and schedule charts’.

The function of follow-up is to report daily the progress of work in each shop in a
prescribed pro forma and to investigate the causes of deviations from the planned performance.

QUALITY CONTROL

Quality Control (QC) may be defined as ‘a system that is used to maintain a desired level of
quality in a product or service’. It is a systematic control of various factors that affect the quality of
the product. Quality control aims at prevention of defects at the source, relies on effective
feedback system and corrective action procedure.

Quality control can also be defined as ‘that industrial management technique by means of
which product of uniform acceptable quality is manufactured’. It is the entire collection of
activities which ensures that the operation will produce the optimum quality products at minimum
cost. The main objectives of quality control are:

To improve the companies income by making the production more acceptable to the
customers i.e., by providing long life, greater usefulness, maintainability, etc.
To reduce companies cost through reduction of losses due to defects.
To achieve interchangeability of manufacture in large scale production.
 22

To produce optimal quality at reduced price.

To ensure satisfaction of customers with productions or services or high quality level, to build
customer goodwill, confidence and reputation of manufacturer.
To make inspection prompt to ensure quality control.
To check the variation during manufacturing.

MATERIALS MANAGEMENT

Materials management is that aspect of management function which is primarily

concerned with the acquisition, control and use of materials needed and flow of goods and
services connected with the production process having some predetermined objectives in view.
The main objectives of materials management are:

1. To minimize material cost.

2. To purchase, receive, transport and store materials efficiently and to reduce the
related cost.
3. To cut down costs through simplification, standardization, value analysis, import
substitution, etc.
4. To trace new sources of supply and to develop cordial relations with them in order
to ensure continuous supply at reasonable rates.
5. To reduce investment tied in the inventories for use in other productive purposes
and to develop high inventory turnover ratios.

MAINTENANCE MANAGEMENT

In modern industry, equipment and machinery are a very important part of the total
productive effort. Therefore, their idleness or downtime becomes are very expensive. Hence, it is
very important that the plant machinery should be properly maintained. The main objectives of
maintenance management are:

1. To achieve minimum breakdown and to keep the plant in good working condition at the
lowest possible cost.
2. To keep the machines and other facilities in such a condition that permits them to be used
at their optimal capacity without interruption.
3. To ensure the availability of the machines, buildings and services required by other sections
of the factory for the performance of their functions at optimal return on investment.

MODULE 3: PRODUCTION PLANNING AND CONTROL

Production planning and control is a tool available to the management to achieve the
stated objectives. Thus, a production system is encompassed by the four factors. i.e., quantity,
quality, cost and time. Production planning starts with the analysis of the given data, i.e., demand
 23

for products, delivery schedule etc., and on the basis of the information available, a scheme of
utilization of firms resources like machines, materials and men are worked out to obtain the target
in the most economical way.

Once the plan is prepared, then execution of plan is performed in line with the details given
in the plan. Production control comes into action if there is any deviation between the actual and
planned. The corrective action is taken so as to achieve the targets set as per plan by using control
techniques.

Thus production planning and control can be defined as the “direction and coordination of
firms’ resources towards attaining the prefixed goals.” Production planning and control helps to
achieve uninterrupted flow of materials through production line by making available the materials
at right time and required quantity.

3.1 Need for Planning and Control

The present techno-economic scenario of India emphasize on competitiveness in

manufacturing. Indian industries have to streamline the production activities and attain the
maximum utilization of firms’ resources to enhance the productivity. Production planning and
control serves as a useful tool to coordinate the activities of the production system by proper
planning and control system. Production system can be compared to the nervous system with PPC
as a brain. Production planning and control is needed to achieve:

1. Effective utilization of firms’ resources.

2. To achieve the production objectives with respect to quality, quantity, cost and timeliness
of delivery.
3. To obtain the uninterrupted production flow in order to meet customers varied demand
with respect to quality and committed delivery schedule.
4. To help the company to supply good quality products to the customer on the continuous
basis at competitive rates.

Production planning is a pre-production activity. It is the pre-determination of

manufacturing requirements such as manpower, materials, machines and manufacturing process.

Ray wild defines “Production planning is the determination, acquisition and arrangement of
all facilities necessary for future production of products.” It represents the design of production
system.
Apart from planning the resources, it is going to organize the production.

Based on the estimated demand for company’s products, it is going to establish the
production program to meet the targets set using the various resources.

3.2 Production Control

 24

Despite of planning to the minute details, most of the time it is not possible to achieve
production 100 per cent as per the plan. There may be innumerable factors which affect the
production system and because of which there is a deviation from the actual plan. Some of the
factors that affect are:

1. Non-availability of materials (due to shortage, etc.);

2. Plant, equipment and machine breakdown;
3. Changes in demand and rush orders;
4. Absenteeism of workers; and
5. Lack of coordination and communication between various functional areas of business.

Thus, if there is a deviation between actual production and planned production, the control
function comes into action. Production control through control mechanism tries to take corrective
action to match the planned and actual production. Thus, production control reviews the progress
of the work, and takes corrective steps in order to ensure that programmed production takes
place. The essential steps in control activity are:

1. Initiating the production,

2. Progressing, and
3. Corrective action based upon the feedback and reporting back to the production planning.

3.3 OBJECTIVES OF PRODUCTION PLANNING AND CONTROL

Following are the objectives of production planning and control:

1. Systematic planning of production activities to achieve the highest efficiency in production
of goods/services.
2. To organize the production facilities like machines, men, etc., to achieve stated production
objectives with respect to quantity and quality time and cost.
3. Optimum scheduling of resources.
4. Coordinate with other departments relating to production to achieve regular balanced and
uninterrupted production flow.
5. To conform to delivery commitments.
6. Materials planning and control.
7. To be able to make adjustments due to changes in demand and rush orders.

3.4 PHASES OF PRODUCTION PLANNING AND CONTROL

Production planning and control has three phases namely:

A. Planning Phase
 25

Fig. 5.1 Phases of production planning and control

PLANNING PHASE

Planning is an exercise of intelligent anticipation in order to establish how an objective can be

achieved or a need fulfilled in circumstances, which are invariably restrictive. Production planning
determines the optimal schedule and sequence of operations economic batch quantity, machine
assignment and dispatching priorities for sequencing. It has two categories of planning namely

1. Prior planning
2. Active planning

PRIOR PLANNING

Prior planning means pre-production planning. This includes all the planning efforts, which
are taking place prior to the active planning.

Modules of pre-planning

The modules of prior planning are as follows:

1. Product development and design is the process of developing a new product with all the
features, which are essential for effective use in the field, and designing it accordingly. At
 26

the design stage, one has to take several aspects of design like, design for selling, design for
manufacturing and design for usage.
2. Forecasting is an estimate of demand, which will happen in future. Since, it is only an
estimate based on the past demand, proper care must be taken while estimating it. Given
the sales forecast, the factory capacity, the aggregate inventory levels and size of the work
force, the manager must decide at what rate of production to operate the plant over an
intermediate planning horizon.
3. Aggregate planning aims to find out a product wise planning over the intermediate
planning horizon.
4. Material requirement planning is a technique for determining the quantity and timing for
the acquisition of dependent items needed to satisfy the master production schedule.

ACTIVE PLANNING

The modules of active planning are: Process planning and routing, Materials planning. Tools
planning, Loading, Scheduling etc.

1. Process planning and routing is a complete determination of the specific technological

process steps and their sequence to produce products at the desired quality, quantity and
cost. It determines the method of manufacturing a product selects the tools and
equipment, analyses how the manufacturing of the product will fit into the facilities.
Routing in particular prescribes the flow of work in the plant and it is related to the
considerations of layout, temporary locations for raw materials and components and
materials handling systems.
2. A material planning is a process which determines the requirements of various raw
materials/subassemblies by considering the trade-off between various cost components
like, carrying cost, ordering cost, shortage cost, and so forth.

3. Tools’ planning determines the requirements of various tools by taking process

specification (surface finish, length of the job, overall depth of cut etc.), material
specifications (type of material used, hardness of the material, shape and size of the
material etc.) and equipment specifications (speed range, feed range, depth of cut range
etc.).
4. Loading is the process of assigning jobs to several machines such that there is a load
balance among the machines. This is relatively a complex task, which can be managed with
the help of efficient heuristic procedures.
5. Scheduling is the time phase of loading and determines when and in what sequence the
work will be carried out. This fixes the starting as well as the finishing time for each job.

ACTION PHASE

Action phase has the major step of dispatching. Dispatching is the transition from planning
phase to action phase. In this phase, the worker is ordered to start manufacturing the product.
 27

The tasks which are included in dispatching are job order, store issue order, tool order, time ticket,
inspection order, move order etc.

The job order number is the key item which is to be mentioned in all other reports/orders.
Stores issue order gives instruction to stores to issue materials for manufacturing the product as
per product specifications. As per tooling requirements for manufacturing the product, the tool
order instruct the tool room to issue necessary tools. Time ticket is nothing but a card which is
designed to note down the actual time taken at various processes. This information is used for
deciding the costs for future jobs of similar nature and also for performing variance analysis, which
helps to exercise control.

Job order is the official authorization to the shop floor to start manufacturing the product.
Generally, the process sequence will contain some testing and inspection. So, these are to be
instructed to inspection wing in the form of inspection order for timely testing and inspection so
that the amount of rework is minimized. The manufacture of product involves moving raw
materials/subassemblies to the main line. This is done by a well-designed materials handling
system. So, proper instruction is given to the materials handling facilities for major movements of
materials/subassemblies in the form of a move order. Movements which involve less distance and
fewer loads are managed at the shop floor level based on requests from operators.

CONTROL PHASE

The control phase has the following two major modules:

1. Progress reporting, and
2. Corrective action.

1. PROGRESS REPORTING

In progress reporting, the data regarding what is happening with the job is collected. Also,
it helps to make comparison with the present level of performance. The various data pertaining to
materials rejection, process variations, equipment failures, operator efficiency, operator
absenteeism, tool life, etc., are collected and analyzed for the purpose of progress reporting.
These data are used for performing variance analysis, which would help us to identify critical areas
that deserve immediate attention for corrective actions.

2.CORRECTIVE ACTION

The tasks under corrective action primarily make provisions for an unexpected event. Some
examples of corrective actions are creating schedule flexibility, schedule modifications, capacity
modifications, make or buy decisions, expediting the work, pre-planning, and so on. Due to
unforeseen reasons such as, machine breakdown, labor absenteeism, too much rejection due to
poor material quality etc., it may not be possible to realize the schedule as per the plan. Under
such condition, it is better to reschedule the whole product mix so that we get a clear picture of
the situation to progress further. Under such situation, it is to be re-examined for selecting
appropriate course of action. Expediting means taking action if the progress reporting indicates
 28

deviations from the originally set targets. Pre-planning of the whole affair becomes essential in
case the expediting fails to bring the deviated plan to its right path.

3.5 FUNCTIONS OF PRODUCTION PLANNING AND CONTROLLING

Functions of production planning and controlling is classified into:

1. Pre-planning function
2. Planning function
3. Control function

The functions of production planning and controlling are depicted in the Fig. 5.2.

1. PRE-PLANNING FUNCTION

Pre-planning is a macro level planning and deals with analysis of data and is an outline
of the planning policy based upon the forecasted demand, market analysis and product
design and

Fig. 5.2 Functions of production planning and control

development. This stage is concerned with process design (new processes and developments,
equipment policy and replacement and work flow (Plant layout). The pre-planning function of PPC
is concerned with decision-making with respect to methods, machines and work flow with respect
to availability, scope and capacity.

2. PLANNING FUNCTION

The planning function starts once the task to be accomplished is specified, with the analysis of
four M’s, i.e., Machines, Methods, Materials and Manpower. This is followed by process planning
 29

(routing). Both short-term (near future) and long-term planning are considered. Standardization,
simplification of products and processes are given due consideration.

3. CONTROL FUNCTION

Control phase is effected by dispatching, inspection and expediting materials control,

analysis of work-in-process. Finally, evaluation makes the PPC cycle complete and corrective
actions are taken through a feedback from analysis. A good communication, and feedback system
is essential to enhance and ensure effectiveness of PPC.

Parameters for PPC

The functions of PPC can be explained with the following parameters:

1. Materials: Raw materials, finished parts and bought out components should be made
available in required quantities and at required time to ensure the correct start and end for each
operation resulting in uninterrupted production. The function includes the specification of
materials (quality and quantity) delivery dates, variety reduction (standardization) procurement
and make or buy decisions.

2. Machines and equipment: This function is related with the detailed analysis of available
production facilities, equipment down time, maintenance policy procedure and schedules.
Concerned with economy of jigs and fixtures, equipment availability. Thus, the duties include the
analysis of facilities and making their availability with minimum down time because of
breakdowns.

3. Methods: This function is concerned with the analysis of alternatives and selection of the
best method with due consideration to constraints imposed. Developing specifications for
processes is an important aspect of PPC and determination of sequence of operations.

4. Process planning (Routing): It is concerned with selection of path or route which the raw
material should follow to get transformed into finished product. The duties include:
(a) Fixation of path of travel giving due consideration to layout.
(b) Breaking down of operations to define each operation in detail.
(c) Deciding the set up time and process time for each operation.

5. Estimating: Once the overall method and sequence of operations is fixed and process sheet
for each operation is available, then the operations times are estimated. This function is carried
out using extensive analysis of operations along with methods and routing and a standard time for
operation are established using work measurement techniques.

6. Loading and scheduling: Scheduling is concerned with preparation of machine loads and
fixation of starting and completion dates for each of the operations. Machines have to been
 30

loaded according to their capability of performing the given task and according to their capacity.
Thus the duties include:
(a) Loading, the machines as per their capability and capacity.
(b) Determining the start and completion times for each operation.
(c) To coordinate with sales department regarding delivery schedules.

7. Dispatching: This is the execution phase of planning. It is the process of setting production
activities in motion through release of orders and instructions. It authorizes the start of production
activities by releasing materials, components, tools, fixtures and instruction sheets to the
operator. The activities involved are:
(a) To assign definite work to definite machines, work centers and men.
(b) To issue required materials from stores.
(c) To issue jigs, fixtures and make them available at correct point of use.
(d) Release necessary work orders, time tickets, etc., to authorize timely start of operations.
(e) To record start and finish time of each job on each machine or by each man.

8. Expediting: This is the control tool that keeps a close observation on the progress of the
work. It is logical step after dispatching which is called ‘follow-up’. It coordinates extensively to
execute the production plan. Progressing function can be divided into three parts, i.e., follow up of
materials, follow up of work-in-process and follow up of assembly. The duties include:
(a) Identification of bottlenecks and delays and interruptions because of which the
production schedule may be disrupted.
(b) To devise action plans (remedies) for correcting the errors.
(c) To see that production rate is in line with schedule.

9. Inspection: It is a major control tool. Though the aspects of quality control are the separate
function, this is of very much important to PPC both for the execution of the current plans and its
scope for future planning. This forms the basis for knowing the limitations with respects to
methods, processes, etc., which is very much useful for evaluation phase.

10. Evaluation: This stage though neglected is a crucial to the improvement of productive
efficiency. A thorough analysis of all the factors influencing the production planning and control
helps to identify the weak spots and the corrective action with respect to pre-planning and
planning will be effected by a feedback. The success of this step depends on the communication,
data and information gathering and analysis.

3.6 OPERATIONS PLANNING AND SCHEDULING SYSTEMS

Operations planning and scheduling systems concern with the volume and timing of outputs,
the utilization of operations capacity at desired levels for competitive effectiveness. These systems
must fit together activities at various levels, from top to bottom, in support of one another, as
shown in Fig. 5.3. Note that the time orientation ranges from long to short as we progress from
 31

top to bottom in the hierarchy. Also, the level of detail in the planning process ranges from broad
at the top to detail at the bottom.

Components of Operations Planning and Scheduling System

1. THE BUSINESS PLAN

The business plan is a statement of the organization’s overall level of business activity for
the coming six to eighteen months, usually expressed in terms of outputs (in volume of sales) for
its various product groups, a set of individual products that share or consume common blocks of
capacity in the manufacturing process. It also specifies the overall inventory and backlog levels
that will be maintained during the planning period. The business plan is an agreement between all
functional areas—finance, production, marketing, engineering, R & D—about the level of activity
and the products they are committed to support. The business plan is not concerned with all the
details and specific timing of the actions for executing the plan. Instead, it determines a feasible
general posture for competing to achieve its major goals. The resulting plan guides the lower-level,
more details decisions.

2. AGGREGATE PRODUCTION (OUTPUT) PLANNING

The process of determining output levels of product groups over the coming six to eighteen
months on a weekly or monthly basis. It identifies the overall level of outputs in support of the
business plan. The plan recognizes the division’s existing fixed capacity and the company’s overall
policies for maintaining inventories and backlogs, employment stability and subcontracting.

3. AGGREGATE CAPACITY PLANNING

It is the process of testing the feasibility of aggregate output plans and evaluating overall
capacity utilization. A statement of desired output is useful only if it is feasible. Thus, it addresses
the supply side of the firm’s ability to meet the demand. As for aggregate output plans, each plant,
facility, or division requires its own aggregate capacity plan. Capacity and output must be in
balance, as indicated by the arrow between them in Fig. 5.3. A capacity plan translates an output
plan into input terms, approximating how much of the division’s capacity will be consumed.
Although these basic capacities are fixed, management can manipulate the short-term capacities
by the ways they deploy their work force, by subcontracting, or by using multiple work shifts to
adjust the timing of overall outputs. As a result, the aggregate planning process balances output
levels, capacity constraints, and temporary capacity adjustments to meet demand and utilize
capacity at desired levels during the coming months. The resulting plan sets limits on the master
production schedule.

4. MASTER PRODUCTION SCHEDULING (MPS)

MPS is a schedule showing week by week how many of each product must be produced
according to customer orders and demand forecasts. Its purpose is to meet the demand for
individual products in the product group. This more detailed level of planning disaggregates the
 32

product groups into individual products and indicates when they will be produced. The MPS is an
important link between marketing and production. It shows when incoming sales orders can be
scheduled into production, and when each shipment can be scheduled for delivery. It also takes
into account current backlogs so that production and delivery schedules are realistic.

Fig. 5.3 Operations planning and scheduling system

5. RESOURCE REQUIREMENT PLANNING

Resource requirement planning (rough-cut capacity planning) is the process of testing the
feasibility of master production schedule in terms of capacity. This step ensures that a proposed
MPS does not inadvertently overload any key department, work center, or machine, making the
MPS unworkable.

6. MATERIAL REQUIREMENT PLANNING

 33

Material requirement planning (MRP) is a system of planning and scheduling the time phased
material requirements for releasing materials and receiving materials that enable the master
production schedule to be implemented. Thus, the master production schedule is the driving force
for material requirements planning. MRP provides information such as due dates for components
that are subsequently used for shop floor control. Once this information is available, it enables
managers to estimate the detailed requirements for each work centers.

7. CAPACITY REQUIREMENT PLANNING

Capacity requirement planning (CRP) is an iterative process of modifying the MPS or planned
resources to make capacity consistent with the production schedule. CRP is a companion process
used with MRP to identify in detail the capacity required to execute the material requirement
planning. At this level, more accurate comparisons of available and needed capacity for scheduled
workloads are possible.

8. SHOP FLOOR CONTROL

Shop floor control involves the activities that execute and control shop operations namely
loading, sequencing, detailed scheduling and expediting jobs in production. It coordinates the
weekly and daily activities that get jobs done. Individual jobs are assigned to machines and work
centers (loading), the sequence of processing the jobs for priority control is determined, start
times and job assignments for each stage of processing are decided (detailed scheduling ) and
materials and work flows from station to station are monitored and adjusted (expediting).

9. LOADING

Each job (customer order) may have its unique product specification and, hence, it is unique
through various work centers in the facility. As new job orders are released, they are assigned or
allocated among the work centers, thus establishing how much of a load each work center must
carry during the coming planning period. This assignment is known as loading (sometimes called
shop loading as machine loading).

10. SEQUENCING

This stage establishes the priorities for jobs in the queues (waiting lines) at the work centers.
Priority sequencing specifies the order in which the waiting jobs are processed; it requires the
adoption of a priority sequencing rule.

11. DETAILED SCHEDULING

Detailed scheduling determines start times, finish times and work assignments for all jobs at
each work center. Calendar times are specified when job orders, employees, and materials
(inputs), as well as job completion (outputs), should occur at each work center. By estimating how
long each job will take to complete and when it is due, schedulers can establish start and finish
dates and develop the detailed schedule.
 34

12. EXPEDITING

Expediting is a process of tracking a job’s progress and taking special actions to move it
through the facility. In tracking a job’s progress, special action may be needed to keep the job
moving through the facility on time. Manufacturing or service operations disruptions-equipment
breakdowns, unavailable materials, last-minute priority changes, require managers to deviate
from plans and schedules and expedite an important job on a special handling basis.

13. INPUT/OUTPUT CONTROL

Input/output control related to the activities to monitor actual versus planned utilization of a
work center’s capacity. Output plans and schedules call for certain levels of capacity at a work
center, but actual utilization may differ from what was planned. Actual versus planned utilization
of the work center’s capacity can be monitored by using input-output reports and, when
discrepancies exist, adjustments can be made. The important components of operations planning
and scheduling system has been explained in detail in the following paragraphs.

AGGREGATE PLANNING

Aggregate planning is an intermediate term planning decision. It is the process of planning

the quantity and timing of output over the intermediate time horizon (3 months to one year).
Within this range, the physical facilities are assumed to –10 be fixed for the planning period.
Therefore, fluctuations in demand must be met by varying labor and inventory schedule.
Aggregate planning seeks the best combination to minimize costs.

Aggregate Planning Strategies

The variables of the production system are labor, materials and capital. More labour effort is
required to generate higher volume of output. Hence, the employment and use of overtime (OT)
are the two relevant variables. Materials help to regulate output. The alternatives available to the
company are inventories, back ordering or subcontracting of items.
These controllable variables constitute pure strategies by which fluctuations in demand and
uncertainties in production activities can be accommodated by using the following steps:
1. Vary the size or the workforce: Output is controlled by hiring or laying off workers in
proportion to changes in demand.
2. Vary the hours worked: Maintain the stable workforce, but permit idle time when there is a
slack and permit overtime (OT) when demand is peak.
3. Vary inventory levels: Demand fluctuations can be met by large amount of inventory.
4. Subcontract: Upward shift in demand from low level. Constant production rates can be met
by using subcontractors to provide extra capacity.

Aggregate Planning Guidelines

The following are the guidelines for aggregate planning:

 35

1. Determine corporate policy regarding controllable variables.

2. Use a good forecast as a basis for planning.
3. Plan in proper units of capacity.
4. Maintain the stable workforce.
5. Maintain needed control over inventories.
6. Maintain flexibility to change.
7. Respond to demand in a controlled manner.
8. Evaluate planning on a regular base.

MASTER PRODUCTION SCHEDULE

Master scheduling follows aggregate planning. It expresses the overall plans in terms
of specific end items or models that can be assigned priorities. It is useful to plan for the
material and capacity requirements.

Flowchart of aggregate plan and master production schedule is shown in Fig. 5.4
Time interval used in master scheduling depends upon the type, volume, and component lead
times of the products being produced. Normally weekly time intervals are used. The time horizon
covered by the master schedule also depends upon product characteristics and lead times. Some
master schedules cover a period as short as few weeks and for some products it is more than a
year.

Functions of MPS

Master Production Schedule (MPS) gives a formal details of the production plan and converts
this plan into specific material and capacity requirements. The requirements with respect to labor,
material and equipment is then assessed. The main functions of MPS are:
1. To translate aggregate plans into specific end items: Aggregate plan determines level of
operations that tentatively balances the market demands with the material, labour and
equipment capabilities of the company. A master schedule translates this plan into specific
number of end items to be produced in specific time period.
 36

Fig. 5.4 Flowchart of aggregate plan and master schedule

2. Evaluate alternative schedules: Master schedule is prepared by trial and error. Many
computer simulation models are available to evaluate the alternate schedules.
3. Generate material requirement: It forms the basic input for material requirement planning
(MRP).
4. Generate capacity requirements: Capacity requirements are directly derived from MPS.
Master scheduling is thus a prerequisite for capacity planning.
5. Facilitate information processing: By controlling the load on the plant. Master schedule
determines when the delivery should be made. It coordinates with other management
information systems such as, marketing, finance and personnel.
6. Effective utilization of capacity: By specifying end item requirements schedule establishes
the load and utilization requirements for machines and equipment.

MATERIAL REQUIREMENT PLANNING (MRP)

MRP refers to the basic calculations used to determine components required from end
item requirements. It also refers to a broader information system that uses the
dependence relationship to plan and control manufacturing operations.

“Materials Requirement Planning (MRP) is a technique for determining the quantity and
timing for the acquisition of dependent demand items needed to satisfy master production
schedule requirements.”
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Objectives of MRP

1. Inventory reduction: MRP determines how many components are required when they are
required in order to meet the master schedule. It helps to procure the materials/ components as
and when needed and thus avoid excessive build up of inventory.
2. Reduction in the manufacturing and delivery lead times: MRP identifies materials and
component quantities, timings when they are needed, availabilities and procurements and actions
required to meet delivery deadlines. MRP helps to avoid delays in production and priorities
production activities by putting due dates on customer job order.
3. Realistic delivery commitments: By using MRP, production can give marketing timely
information about likely delivery times to prospective customers.
4. Increased efficiency: MRP provides a close coordination among various work centers and
hence help to achieve uninterrupted flow of materials through the production line. This increases
the efficiency of production system.

MRP System

The inputs to the MRP system are: (1) A master production schedule, (2) An inventory status
file and (3) Bill of materials (BOM).
Using these three information sources, the MRP processing logic (computer program) provides
three kinds of information (output) for each product component: order release requirements,
order rescheduling and planned orders.

1. MASTER PRODUCTION SCHEDULE (MPS)

MPS is a series of time phased quantities for each item that a company produces, indicating
how many are to be produced and when. MPS is initially developed from firm customer orders or
from forecasts of demand before MRP system begins to operate. The MRP system whatever the
master schedule demands and translates MPS end items into specific component requirements.
Many systems make a simulated trial run to determine whether the proposed master can be
satisfied.
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2. INVENTORY STATUS FILE

Every inventory item being planned must have an inventory status file which gives
complete and up to date information on the on-hand quantities, gross requirements,
scheduled receipts and planned order releases for an item. It also includes planning
information such as lot sizes, lead times, safety stock levels and scrap allowances.

3. BILL OF MATERIALS (BOM)

BOM identifies how each end product is manufactured, specifying all subcomponents
items, their sequence of build up, their quantity in each finished unit and the work centers
performing the build up sequence. This information is obtained from product design
documents, workflow analysis and other standard manufacturing information.

CAPACITY PLANNING

Design of the production system involves planning for the inputs, conversion process
and outputs of production operation. The effective management of capacity is the most
important responsibility of production management. The objective of capacity management
(i.e., planning and control of capacity) is to match the level of operations to the level of
demand.

Capacity planning is to be carried out keeping in mind future growth and expansion
plans, market trends, sales forecasting, etc. It is a simple task to plan the capacity in case of
stable demand. But in practice the demand will be seldom stable. The fluctuation of demand
creates problems regarding the procurement of resources to meet the customer demand.
Capacity decisions are strategic in nature. Capacity is the rate of productive capability of a
facility. Capacity is usually expressed as volume of output per period of time.

Production managers are more concerned about the capacity for the following reasons:

Sufficient capacity is required to meet the customers demand in time.

Capacity affects the cost efficiency of operations.
Capacity affects the scheduling system.
Capacity creation requires an investment.
Capacity planning is the first step when an organization decides to produce more or new
products.

MEASUREMENT OF CAPACITY PLANNING

The capacity of the manufacturing unit can be expressed in number of units of output
per period. In some situations measuring capacity is more complicated when they
manufacture multiple products. In such situations, the capacity is expressed as man-hours or
machine hours. The relationship between capacity and output is shown in Fig. 5.6.
 39

1. Design capacity: Designed capacity of a facility is the planned or engineered rate of output
of goods or services under normal or full scale operating conditions.
For example, the designed capacity of the cement plant is 100 TPD (Tons per day). Capacity of
the sugar factory is 150 tons of sugarcane crushing per day.

2. System capacity: System capacity is the maximum output of the specific product or
product mix the system of workers and machines is capable of producing as an integrated whole.
System capacity is less than design capacity or at the most equal, because of the limitation of
product mix, quality specification, breakdowns. The actual is even less because of many factors
affecting the output such as actual demand, downtime due to machine/equipment failure,
unauthorized absenteeism.

Fig. 5.6 Capacity and output relationship

The system capacity is less than design capacity because of long range uncontrollable factors.
The actual output is still reduced because of short-term effects such as, breakdown of equipment,
inefficiency of labor. The system efficiency is expressed as ratio of actual measured output to the
system capacity.
Actual output
System Efficiency (SE) =
System capacity
3. Licensed capacity: Capacity licensed by the various regulatory agencies or government
authorities. This is the limitation on the output exercised by the government.
4. Installed capacity: The capacity provided at the time of installation of the plant is called
installed capacity.
5. Rated capacity: Capacity based on the highest production rate established by actual trials
is referred to as rated capacity.

PROCESS OF CAPACITY PLANNING

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Capacity planning is concerned with defining the long-term and the short-term capacity needs
of an organization and determining how those needs will be satisfied. Capacity planning decisions
are taken based upon the consumer demand and this is merged with the human, material and
financial resources of the organization.

Capacity requirements can be evaluated from two perspectives—long-term capacity strategies

and short-term capacity strategies.

1. LONG-TERM CAPACITY STRATEGIES

Long-term capacity requirements are more difficult to determine because the future demand
and technology are uncertain. Forecasting for five or ten years into the future is more risky and
difficult. Even sometimes company’s today’s products may not be existing in the future. Long
range capacity requirements are dependent on marketing plans, product development and
lifecycle of the product. Long-term capacity planning is concerned with accommodating major
changes that affect overall level of the output in long-term. Marketing environmental assessment
and implementing the long-term capacity plans in a systematic manner are the major
responsibilities of management. Following parameters will affect long range capacity decisions.
1. Multiple products: Company’s produce more than one product using the same facilities in
order to increase the profit. The manufacturing of multiple products will reduce the risk of failure.
Having more than one product helps the capacity planners to do a better job. Because products
are in different stages of their life-cycles, it is easy to schedule them to get maximum capacity
utilization.
2. Phasing in capacity: In high technology industries, and in industries where technology
developments are very fast, the rate of obsolescence is high. The products should be brought into
the market quickly. The time to construct the facilities will be long and there is no much time as
the products should be introduced into the market quickly. Here the solution is phase in capacity
on modular basis. Some commitment is made for building funds and men towards facilities over a
period of 3–5 years. This is an effective way of capitalizing on technological breakthrough.
3. Phasing out capacity: The outdated manufacturing facilities cause excessive plant closures
and down time. The impact of closures is not limited to only fixed costs of plant and machinery.
Thus, the phasing out here is done with humanistic way without affecting the community. The
phasing out options makes alternative arrangements for men like shifting them to other jobs or to
other locations, compensating the employees, etc.
2. SHORT-TERM CAPACITY STRATEGIES
Managers often use forecasts of product demand to estimate the short-term workload the
facility must handle. Managers looking ahead up to 12 months, anticipate output requirements for
different products, and services. Managers then compare requirements with existing capacity and
then take decisions as to when the capacity adjustments are needed.

For short-term periods of up to one year, fundamental capacity is fixed. Major facilities will
not be changed. Many short-term adjustments for increasing or decreasing capacity are possible.
The adjustments to be required depend upon the conversion process like whether it is capital
intensive or labor intensive or whether product can be stored as inventory.
 41

Capital intensive processes depend on physical facilities, plant and equipment. Short-term
capacity can be modified by operating these facilities more or less intensively than normal. In labor
intensive processes short-term capacity can be changed by laying off or hiring people or by giving
overtime to workers. The strategies for changing capacity also depend upon how long the product
can be stored as inventory.

The short-term capacity strategies are:

1. Inventories: Stock of finished goods during slack periods to meet the demand during peak
period.
2. Backlog: During peak periods, the willing customers are requested to wait and their orders
are fulfilled after a peak demand period.
3. Employment level (hiring or firing): Hire additional employees during peak demand period
and layoff employees as demand decreases.
4. Employee training: Develop multi-skilled employees through training so that they can be
rotated among different jobs. The multi-skilling helps as an alternative to hiring employees.
5. Subcontracting: During peak periods, hire the capacity of other firms temporarily to make
the component parts or products.
6. Process design: Change job contents by redesigning the job.

ROUTING

Routing may be defined as the selection of path which each part of the product will follow
while being transformed from raw materials to finished products. Path of the product will also give
sequence of operation to be adopted while being manufactured.

In other way, routing means determination of most advantageous path to be followed from
department to department and machine to machine till raw material gets its final shape, which
involves the following steps:
(a) Type of work to be done on product or its parts.
(b) Operation required to do the work.
(c)Sequence of operation required. Where the work will be done.
(d)A proper classification about the personnel required and the machine for doing the work.
For effective production control of a well-managed industry with standard conditions, the
routing plays an important role, i.e., to have the best results obtained from available plant
capacity. Thus routing provides the basis for scheduling, dispatching and follow-up.

Techniques of Routing

While converting raw material into required goods different operations are to be performed
and the selection of a particular path of operations for each piece is termed as ‘Routing’. This
selection of a particular path, i.e. sequence of operations must be the best and cheapest to have
the lowest cost of the final product. The various routing techniques are:
1.Route card: This card always accompanies with the job throughout all operations. This
indicates the material used during manufacturing and their progress from one operation
 42

to another. In addition to this the details of scrap and good work produced are also
recorded.
2.Work sheet: It contains
(a) Specifications to be followed while manufacturing.
(b) Instructions regarding routing of every part with identification number of machines and
work place of operation.
This sheet is made for manufacturing as well as for maintenance.
3.Route sheet: It deals with specific production order. Generally made from operation
sheets.
One sheet is required for each part or component of the order. These includes the
following:
(a) Number and other identification of order.
(b) Symbol and identification of part.
(c) Number of pieces to be made.
(d) Number of pieces in each lot—if put through in lots.
(e) Operation data which includes:
(i) List of operation on the part.
(ii) Department in which operations are to be performed.
(iii) Machine to be used for each operation.
(iv) Fixed sequence of operation, if any.
(f) Rate at which job must be completed, determined from the operation sheet.
1. Move order: Though this is document needed for production control, it is never used for
routing system. Move order is prepared for each operation as per operation sheet. On this the
quantity passed forward, scrapped and to be rectified are recorded. It is returned to
planning office when the operation is completed.

SCHEDULING

Scheduling can be defined as “prescribing of when and where each operation necessary to
manufacture the product is to be performed.”

It is also defined as “establishing of times at which to begin and complete each event or
operation comprising a procedure”. The principle aim of scheduling is to plan the sequence of
work so that production can be systematically arranged towards the end of completion of all
products by due date.

Principles of Scheduling

1. The principle of optimum task size: Scheduling tends to achieve maximum efficiency when
the task sizes are small, and all tasks of same order of magnitude.
2. Principle of optimum production plan: The planning should be such that it imposes an
equal load on all plants.
3. Principle of optimum sequence: Scheduling tends to achieve the maximum efficiency when
the work is planned so that work hours are normally used in the same sequence.
 43

Inputs to Scheduling
1. Performance standards: The information regarding the performance standards (standard
times for operations) helps to know the capacity in order to assign required machine hours
to the facility.
2. Units in which loading and scheduling is to be expressed.
3. Effective capacity of the work center.
4. Demand pattern and extent of flexibility to be provided for rush orders.
5. Overlapping of operations.
6. Individual job schedules.

Scheduling Strategies

Scheduling strategies vary widely among firms and range from ‘no scheduling’ to very
sophisticated approaches.

These strategies are grouped into four classes:

1. Detailed scheduling: Detailed scheduling for specific jobs that are arrived from customers
is impracticable in actual manufacturing situation. Changes in orders, equipment breakdown, and
unforeseen events deviate the plans.
2. Cumulative scheduling: Cumulative scheduling of total work load is useful especially for
long range planning of capacity needs. This may load the current period excessively and under load
future periods. It has some means to control the jobs.
3. Cumulative detailed: Cumulative detailed combination is both feasible and practical
approach. If master schedule has fixed and flexible portions.
4. Priority decision rules: Priority decision rules are scheduling guides that are used
independently and in conjunction with one of the above strategies, i.e., first come first serve.
These are useful in reducing Work-In-Process (WIP) inventory.

Types of Scheduling

Types of scheduling can be categorized as forward scheduling and backward scheduling.

1. Forward scheduling is commonly used in job shops where customers place their orders on
“needed as soon as possible” basis. Forward scheduling determines start and finish times of next
priority job by assigning it the earliest available time slot and from that time, determines when the
job will be finished in that work center. Since the job and its components start as early as possible,
they will typically be completed before they are due at the subsequent work centers in the
routing. The forward method generates in the process inventory that are needed at subsequent
work centers and higher inventory cost. Forward scheduling is simple to use and it gets jobs done
in shorter lead times, compared to backward scheduling.
2. Backward scheduling is often used in assembly type industries and commit in advance to
specific delivery dates. Backward scheduling determines the start and finish times for waiting jobs
 44

by assigning them to the latest available time slot that will enable each job to be completed just
when it is due, but done before. By assigning jobs as late as possible, backward scheduling
minimizes inventories since a job is not completed until it must go directly to the next work center
on its routing. Forward and backward scheduling methods are shown in Fig. 5.7.

Scheduling Methodology

The scheduling methodology depends upon the type of industry, organization, product, and
level of sophistication required. They are:
1.Charts and boards,
2.Priority decision rules, and
3.Mathematical programming methods.
1. Gantt Charts and Boards
Gantt charts and associated scheduling boards have been extensively used scheduling devices
in the past, although many of the charts are now drawn by computer. Gantt charts are extremely
easy to understand and can quickly reveal the current or planned situation to all concerned. They
are used in several forms, namely,
(a) Scheduling or progress charts, which depicts the sequential schedule;
(b) Load charts, which show the work assigned to a group of workers or machines; and
(c) Record a chart, which are used to record the actual operating times and delays of workers
and machines.
2. Priority Decision Rules
Priority decision rules are simplified guidelines for determining the sequence in which jobs will
be done. In some firms these rules take the place of priority planning systems such as MRP
systems. Following are some of the priority rules followed.

Symbo Priority rule

 45

l
FCFS First come, first served
EDO Earliest due date
LS Least slack (that is, time due less processing
time)
SPT Shortest processing time
LPT Longest processing time
PCO Preferred customer order
RS Random selection
3. Mathematical Programming Methods
Scheduling is a complex resource allocation problem. Firms process capacity, labor skills,
materials and they seek to allocate their use so as to maximize a profit or service objective, or
perhaps meet a demand while minimizing costs.
The following are some of the models used in scheduling and production control.
(a) Linear programming model: Here all the constraints and objective functions are
formulated as a linear equation and then problem is solved for optimality. Simplex method,
transportation methods and assignment method are major methods used here.
(b)PERT/CPM network model: PERT/CPM network is the network showing the sequence of
operations for a project and the precedence relation between the activities to be completed.
Note: Scheduling is done in all the activities of an organization i.e., production, maintenance
etc. Therefore, all the methods and techniques of scheduling is used for maintenance
management.

EXERCISES
 46

Section A
1. What do you mean by production planning and control?
2. What do you mean by aggregate planning?
3. What is master production schedule?
4. What is material requirement planning?
5. What is capacity planning?
6. What is routing?
7. What is scheduling?
8. Mention the types of scheduling.
Section B
1. Why do you need production planning and control?
2. What are the objective of production planning and control?
3. What are the guidelines for aggregate planning?
4. Explain the functions of master production schedule.
5. Explain the objective of MRP.
6. How do you measure capacity?
7. Explain the techniques of routing.
8. What are the inputs to scheduling?
9. Explain the scheduling strategies.
Section C
1. Discuss the phases of production planning and control.
2. Discuss the functions of PP & C.
3. Discuss the operations planning and scheduling systems.
4. Discuss the aggregate plan and master schedule.
5. Discuss the MRP system.
6. Discuss the process of capacity planning.
7. Discuss the scheduling methods.
Skill Development
FAST FOOD RESTAURANT VISIT: Get the information for the following questions:
1. Phase of production planning and production control.
2. Planning for the demand fluctuation.
3. Items are prepared to order or with forecast.
4. Procedures to manufacture pizza.
Scheduling the orders (i.e. first come first schedule or largest proceeding time and shortes