GROUP 9

CABALTERA, JEROME A.
ABEJERO, JAMESPAUL A
BANAN, JUDE ARGEL
NASOL XYRA VIENN
ALINSUNURIN, ILET JONAH
PRODUCTION PLANNING
AND CONTROL
 PRODUCTION PLANNING

Production planning – is the function of looking ahead

anticipating difficulties to be faced and the likely
remedial steps to remove them. It may be said to be a
technique of forecasting ahead every steps in the long
process, taking them at a right time and in the right
degree and trying to complete the operations at
maximum efficiency.
 PRODUCTION control

Production Control – is to guide and directs flow of

production so that the products are manufactured in a
best way and conform to a planned schedule and are
of the right quality
 Objective PRODUCTION
PLANNING AND CONTROL
OBJECTIVE IN PRODUCTION PLANNING
AND CONTROL

Planning of production precedes

control. Whatever is planned needs to be
controlled. The ultimate objective of both
planning and control is to use various
inputs in an efficient way.
PRODUCTION PLANNING

1. Making most economical use of various inputs.

2. To Determine the requirements for men, materials and
machines.
3. Production of various inputs at a right time and in a right
quantity and the right quality.
4. Arranging production schedules according to the needs of
marketing department.
5. Providing for adequate stocks to meet contingencies.
6. Keeping up-to-date information processes.
PRODUCTION CONTROL

1. Making efforts to adhere to the production schedules.

2. Issuing necessary instructions to the staff making the plans
effective.
3. To ensure the goods produced according to the prescribed
standards and quality norms.
4. To ensure that various inputs are made available in the right
quantity and proper time.
5. To ensure that work progresses according to the predefined
plans.
Stages of Production Planning and Control

1. Planning Phase

2. Action Phase
3. Control Phase
PLANNING PHASE

Planning is an exercise of intelligent

anticipation in order to establish how an
objective can be achieved or a fulfilled in
restrictive circumstances.
PLANNING PHASE

1. PRIOR PLANNING
2. ACTIVE PLANNING
PRIOR PLANNING

Prior planning means pre-production

planning. This include all the planning
efforts, which are taking place prior to the
active planning.
MODULES

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 the design stage, one has to take several
aspects of design like, design for selling,
design for manufacturing design for usage.
MODULES

Forecasting is an estimate of demand ,

which will happen in the future. Since, it
is only an estimate based on the past
demand, proper care must be taken while
estimating it.
MODULES

Aggregate planning aims to find out a

product wise planning over the
intermediate planning horizon.
MODULES

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

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.
ACTIVE PLANNING

2. A material planning is a process which

determines the requirements of various
raw materials by considering the trade-off
between various cost components like,
carrying cost, ordering cost, shortage cost,
and so forth.
ACTIVE PLANNING

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 specification (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.)
ACTIVE PLANNING

4. Loading is the process of assigning jobs

to several machine such that there is a load
balance among the machines.
ACTIVE PLANNING

5. Scheduling is the time phase o loading

and determine 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 dispatching.

Dispatching is the transition from planning
phase to action phase. In this phase, the worker
is ordered to start manufacturing the product.
The tasks which are included in dispatching are
job order, store issue, tool order, time ticket,
inspection order, move order etc.
ACTION PHASE

The job order number is the key item which

is to be mentioned in all other reports/orders.
Stores issue order gives instruction to store
to issue materials for manufacturing the
product, the tool Order instruct the tool room
to issue necessary tools.
ACTION PHASE

Time ticket is nothing but a card which is

designed to note down the actual time
taken various processes. This information
is used for deciding the costs for future
jobs of similar nature and also for
performing variance analysis.
CONTROL PHASE

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 analysed
for the purpose of progress reporting.
CONTROL PHASE

Corrective Action: The task 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 by decisions, expediting the work,
pre-planning, and so on. Due to unforeseen reasons such
as, machine breakdown, labour absenteeism, too much
rejection due to poor material quality etc.,
 Functions/scope of
production planning &
control
 Functions/scope of production planning & control

1. MATERIALS – Materials should be made available at the right quality, quantity and price.
Inventory control & regular supply of materials should be guaranteed.

2. MANPOWER – It is important to carry out manpower planning to maintain operational &

managerial staff possessing requisite skills & expertise.

3. METHODS – It is always desirable to consider all the available alternatives & select the
best method of processing.

4. MACHINES & EQUIPMENTS – The choices of manufacturing methods depend on

available production facilities & utilization of plant, machine equipment.

5. ROUTING – The routing function specifies what work is to be done where & when it is to
be performed.
 Functions/scope of production planning & control

6. ESTIMATING – It involves establishing performance standard of each work after daily

analyzing operation sheets. These sheets indicates feeds, speeds, depth of cuts, use of special
attachments & methods.

7. LOADING & SCHEDULING – Machines have to be made as per the production

requirements. Machine loading generates accurate information on work standard, scrap
allowance, machine-time requirements & machine capacities. Scheduling is a time-table for
performing the job on the available machines so that delivery dates are maintained.

8. DISPATCHING – Dispatching is the release of orders & instructions as per the route sheets
& schedule charts.

9. EXPEDITING – It refers to follow-up which is done after the dispatching function.

 Functions/scope of production planning & control

10. INSPECTION – It is related to maintenance of quality in production & processes, methods

labour so that improvements can be made to achieve the quality standards.

11. EVALUATING – It provides a feedback mechanism on a long term basis so that past
experience can be used to improve upon use of methods, facilities & resources in future period.

12. COST CONTROL – In manufacturing products, cost can be kept within control through
wastage reduction, value analysis, inventory control & efficient use of resources.
Challenges PRODUCTION
PLANNING AND
CONTROL
COMBINING FUNCTION

It
is desirable that a minimum changes be
made after schedules are established
FOLLOW UP

When jobs are started and completed on

schedule, there should be very little
concern about the meeting of
commitments.
REPLANNING

Often required in manufacturing, changes

in market conditions manufacturing
methods, etc. Affecting the plant will often
indicate that a new manufacturing plan is
required.
 FACTORS AFFECTING
PRODUCTION PLANNING
AND CONTROL
MARKET FORECAST

It will indicate future trends in demand for

manufactured products. Work shift
policies, plans for an increase or decrease
in manufacturing activity are based upon
the market forecast and in turn affect the
production planning and control.
SALES ORDER

Itis a rewrite of the customer order

specifying what has been purchased.
Variation or changes in sales order will
drastically affect production planning and
control.
STANDARD PROCESS SHEET

It is prepared by process engineering

group or process owner and is the source
of basic data which may include type of
machine to be used, time required for
processing etc.
PROJECT PLANNING METHOD

The product to be produced are manufactured in

quantities and their total processing time can be
measured.
The best known methods are:
 Critical Path Method (CPM)
Program Evaluation and Review Technique
(PERT)
 ROLE OF PRODUCTION
PLANNING AND CONTROL IN
MANUFACTURING INDUSTRY
ROLE OF PRODUCTION PLANNING AND CONTROL
IN MANUFACTURING INDUSTRY

1. TAKING THE ORDERS FROM MARKETING

DIVISION.
2. ANALYZING THE
ORDERS.
3. PRODUCTION PLANNING.
• THE QUALITY OBJECTIVE

 To feel the desires of the costumer.  To maintain infrastructural task accurately.

 To implement the required systems.  To build quality into every product at every stages of
production line.
 To assign resources for training & place of
 To obtain a production-line with minimal errors &
work improvements.
corrective actions

4. COST-ANALYSIS.