Elements of Production Planning and Control (PPC)
Summary
TLDRThe script outlines the critical role of production planning and control in an organization. It details the functions of a planning department, which prepares policies, plans, and budgets based on management directives. Key elements include materials planning, method selection, machinery and equipment planning, manpower planning, routing, and the creation of routing sheets. The script also covers estimating, machine loading, scheduling, dispatching, inspection, evaluating, and cost control, emphasizing their importance in achieving production targets and maintaining quality standards.
Takeaways
- 📝 **Production Planning Foundation**: Production planning is the cornerstone of production planning and control, involving advance decisions on future actions.
- 🏢 **Planning Department Role**: A dedicated planning department is established to prepare policies and plans for production, including charts, manuals, and budgets based on management information.
- 🔍 **Production Control Impact**: Deficiencies in production planning directly affect production control, which is crucial for achieving production targets.
- 🛠️ **Materials Planning**: Essential for procuring raw materials, components, and spare parts with the right specifications, at the right time, from the right source.
- 🔧 **Method Selection**: Choosing the best processing method and sequence of operations, including tooling, jigs, and fixtures planning.
- 🏭 **Machines and Equipment**: Production methods are tied to the available manufacturing facilities, involving capacity and utilization planning for plant and equipment.
- 👥 **Manpower Planning**: Involves planning for labor and managerial levels with the appropriate skills and expertise.
- 🔄 **Routing and Flow of Work**: Determining the path of work through the plant, including material handling and the sequence of operations.
- 📑 **Route Sheet Details**: A document outlining each step of production operations, including required machines, tools, and specifications.
- ⏱️ **Operation Times and Standards**: Estimating operation times and setting performance standards for workers and machines based on sales forecasts.
- 🔄 **Machine Loading**: Assigning specific jobs to machines or work centers to maximize resource utilization and avoid bottlenecks.
- ⏰ **Scheduling**: Ensuring timely completion of parts, sub-assemblies, and finished goods to meet delivery dates and optimize resource use.
- 📢 **Dispatching**: Executing planning functions by releasing orders and instructions for production start in line with routing and scheduling.
- 🔍 **Inspection**: Maintaining production quality and evaluating process efficiency for continuous improvement towards quality standards.
- 📊 **Evaluating Performance**: Assessing machine, process, and labor performance to drive improvements and enhance overall efficiency.
- 💰 **Cost Control**: Controlling manufacturing costs through waste reduction, value analysis, inventory control, and resource optimization.
Q & A
What is the primary role of a production plan in production planning and control?
-The primary role of a production plan is to decide in advance what needs to be done in the future, providing a sound basis for production control and ensuring the achievement of production targets.
What is the function of a separate planning department in an organization?
-A separate planning department is responsible for the preparation of policies and plans regarding production, including the creation of charts, manuals, and production budgets based on information received from management.
Why is it important to have a well-prepared production plan?
-A well-prepared production plan is crucial because if it is defective, production control will be adversely affected, which can hinder the achievement of production targets.
What are the key activities associated with material planning in production?
-Key activities associated with material planning include procurement of raw materials, components, spare parts, purchasing, storage, inventory control, standardization, variety reduction, value analysis, and inspection.
What does method planning involve in the context of production planning?
-Method planning involves choosing the best method of processing from several alternatives, determining the best sequence of operations, and planning for tooling, jigs, and fixtures.
How are manufacturing methods related to production facilities in production planning?
-Manufacturing methods are related to the production facilities available in the production systems, involving facilities planning, capacity planning, allocations, and utilization of plant and equipment, machines, etc.
What is the significance of manpower planning in production?
-Manpower planning is significant as it ensures that there is an appropriate workforce with the necessary skills and expertise at both labor and managerial levels to meet production requirements.
What information does a route sheet provide for the production process?
-A route sheet provides information on the operation sequence, machines or equipment used for each operation, estimated setup and operation time per piece, tools and fixtures required, detailed drawings, specifications, dimensions, tolerances, surface finishes, quality standards, raw material specifications, and inspection procedures.
What is the purpose of estimating in production planning?
-The purpose of estimating is to decide the quantity of the product to be produced and the cost involved, based on sales forecasts, to ensure that manpower, machine capacity, and material requirements meet the planned production targets.
How does machine loading contribute to production efficiency?
-Machine loading contributes to production efficiency by assigning specific jobs to machines, men, or work centers based on priorities and capacity utilization, ensuring maximum utilization of productive facilities and avoiding bottlenecks in production.
What is the main goal of scheduling in production planning?
-The main goal of scheduling is to ensure that parts, sub-assemblies, and finished goods are completed as per required delivery dates, providing a timetable for manufacturing activities to prevent unbalanced use of time and to utilize labor efficiently.
What is the role of dispatching in the execution of production planning functions?
-Dispatching is concerned with the execution of planning functions, giving the necessary authority to start a particular work that has already been planned under routing and scheduling, releasing orders and instructions for starting production in accordance with the route sheet and scheduling charts.
Why is inspection important in the context of production planning and control?
-Inspection is important for maintaining quality in production and evaluating the efficiency of processes, methods, and labor, allowing for improvements to be made in order to achieve the quality standards set by product design.
What is the objective of evaluating performance in production planning?
-The objective of evaluating performance is to improve the performance of machines, processes, and labor, with the aim of enhancing overall production efficiency and effectiveness.
How is cost control achieved in manufacturing as part of production planning?
-Cost control in manufacturing is achieved through wastage reduction, value analysis, inventory control, and efficient utilization of all resources to minimize costs while maintaining production quality.
Outlines
📝 Production Planning and Control Overview
This paragraph introduces the fundamental role of production planning in an organization, emphasizing its importance as the first step in production control. It explains that planning involves strategic decisions about future activities and is managed by a dedicated department responsible for creating policies and plans. This department prepares essential documents like charts, manuals, and budgets based on management's input. The paragraph also outlines the negative impact of poor planning on production control and how planning provides a solid foundation for it. It describes production planning as a top-level activity, while control is exercised at the operational level. The paragraph concludes by listing key elements of production planning and control, such as materials planning, method selection, machinery and equipment planning, manpower planning, routing, and the significance of a route sheet in detailing the production process.
📅 The Importance of Scheduling and Dispatching
The second paragraph delves into the purpose of scheduling in production, highlighting its role in preventing unbalanced time usage across work centers and departments. It underscores the importance of utilizing labor efficiently to meet delivery deadlines and minimize production costs. The paragraph then introduces dispatching as the execution of planning functions, which involves releasing orders and instructions to start production as per the routing and scheduling charts. Dispatching ensures that production aligns with the predefined plans. The paragraph also touches on inspection as a crucial function for maintaining quality and evaluating process efficiency. It concludes with an overview of evaluating performance and cost control, explaining how these elements contribute to improving machine, process, and labor performance, and how cost control is achieved through waste reduction and efficient resource utilization.
Mindmap
Keywords
💡Production Planning
💡Production Control
💡Planning Department
💡Materials Planning
💡Method
💡Machines and Equipment
💡Manpower Planning
💡Routing
💡Route Sheet
💡Estimating
💡Loading
💡Scheduling
💡Dispatching
💡Inspection
💡Evaluating
💡Cost Control
Highlights
Production planning is the first and foremost element of production planning and control.
Planning refers to deciding in advance what is to be done in the future.
A separate planning department is established in the organization to prepare policies and plans regarding production.
Production plans are given practical shape by carrying various elements under production control.
If production planning is defective, production control is bound to be adversely affected.
Production planning provides a sound basis for production control.
Production plans are prepared in advance at the top level, while production control is exercised at the machine shop floor level.
Materials planning involves procurement of raw materials, components, and spare parts in the right quantities and specifications.
Method choosing involves selecting the best method of processing from several alternatives.
Machines and equipment planning involves facilities planning, capacity planning, and utilization of plant and equipment.
Manpower planning is for having appropriate skills and expertise at labor and managerial levels.
Routing determines the flow of work, material handling in the plant, and sequence of operations or processing steps.
A route sheet provides information and instructions for converting raw material into finished parts or products.
Estimating involves deciding the quantity of the product to be produced and the cost involved based on sales forecast.
Machine loading is the process of assigning specific jobs to machines, men, or work centers based on priorities and capacity utilization.
Scheduling ensures that parts, sub-assemblies, and finished goods are completed as per required delivery dates.
Dispatching is concerned with the execution of planning functions and gives authority to start a particular work.
Inspection is related to maintaining quality in production and evaluating the efficiency of processes, methods, and labor.
Evaluating aims to improve the performance of machines, processes, and labor.
Cost control involves manufacturing cost control by wastage reduction, value analysis, inventory control, and efficient utilization of resources.
Transcripts
this is important to note that
production plan is the first and the
foremost element of production planning
and control
planning refers to deciding in advance
what is to be done in future
a separate planning department is
established in the organization which is
responsible for the preparation of
policies and plans with regard to
production to be undertaken in due
course
the planning department prepares various
charts manuals production budgets etc
on the basis of information received
from management
these plans and charts or production
budgets are given
practical shape by carrying various
elements under production control
if production planning is defective
production control is bound to be
adversely affected for achieving the
production targets
production planning provides sound basis
for production control
one needs to remember that production
plans are prepared in advance at top
level whereas
production control is exercised at
machine shop floor
bottom level where actual production is
taking place
some important elements of production
planning and control have been depicted
as we can see in this figure
the important elements may be listed as
following
number one materials planning for
procurement of raw material
component and spare parts in the right
quantities and specifications at the
right time from the right source at the
right place
purchasing storage inventory control
standardization variety reduction value
analysis
and inspection are the other activities
associated with material
number two method choosing the best
method of processing form several
alternatives
it also includes determining the best
sequence of operations
process plan and planning for tooling
jigs and fixtures etc
number three machines and equipment
manufacturing methods are related to
production facilities available in
production systems
it involves facilities planning capacity
planning
allocations and utilization of plant and
equipment
machines etc number four manpower
planning for manpower labor and
managerial levels
having appropriate skills and expertise
element number five routing determining
the flow of work
material handling in the plant and
sequence of operations or processing
steps
this is related to consideration of
appropriate shop layout plant layout
temporary storage location for raw
materials component and semi-finished
goods
and of materials handling system now
when we are talking about routing
another important term that comes into
context is
root sheet a root sheet is a document
providing
information and instructions for
converting the raw material in finished
part or product
it defines each step of the production
operations and lay down the precise path
or route through which the product will
flow during the conversion process
route sheet contains following
information
the operation required at their desired
sequence
machines or equipment to be used for
each operations
estimated setup time and operation time
per piece
tools jigs and fixtures required for
operations
detailed drawings of the part
sub-assemblies and final assemblies
specification dimensions tolerances
surface finishes and quality standard to
be achieved
specification of raw material to be used
speed feed etc to be used in machines
tools for operations to be carried on
inspection procedure and metrology tools
required for inspection
packing and handling instructions during
movement of parts and sub-assemblies
through the operation stages
element number six estimating
establishing operation times leading to
fixations of performance standards both
for worker and machines
estimating involves deciding the
quantity of the product which needs to
be produced and cost involved in it on
the basis of sale forecast
estimating manpower machine capacity and
material required meeting the planned
production targets are like the key
activities before budgeting for
resources
number seven loading machine loading is
the process of converting operation
schedule into practices in conjunctions
with routing
machine loading is the process assigning
specific jobs to machines
men or work centers based on relative
priorities and capacity utilization
loading ensures maximum possible
utilization of productive facilities
and avoid bottleneck in production it's
important to either overloading or under
loading the facilities
work centers or machines to ensure
maximum utilization of resources
element number eight scheduling
scheduling ensure that parts and
sub-assemblies and finished goods are
completed as per required delivery dates
it provides a timetable for
manufacturing activities
so what are the purposes of scheduling
we need scheduling to prevent unbalanced
use of time among work
and centers and department and to
utilize labor such a way that output is
produced within established lead time or
cycle time
so as to deliver the products on time
and complete production
in minimum total cost then comes element
number nine
dispatching this is concerned with the
execution of the planning functions
it gives necessary authority to start a
particular work which has already
planned under routing and scheduling
functions
dispatching is release of orders and
instructions for starting of production
in accordance with rooting sheet and
scheduling charts
number 10 inspection this function is
related to maintenance of quality in
production
and of evaluating the efficiency of the
processes
methods and labor so that improvement
can be made to achieve the quality
standards set by
product design number 11 evaluating
the objective of evaluating is to
improve performance
performance of machines processes and
labor is evaluated to improve the same
and finally element number 12 cost
control
manufacturing cost is controlled by
wastage reduction
value analysis inventory control and
efficient utilization of all resources
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