Objectives of 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 and to have a
proper control over various targets and schedules fixed earlier.
Production Planning:
1. To determine the requirements for men,
materials and equipment.
2. Production of various inputs at a
right time and in right quantity.
3. Making most economical use of various
inputs.
4. Arranging production schedules
according to the needs of marketing department.
5. Providing for adequate stocks for
meeting 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 for making the plans realistic.
3. To ensure that goods produced
according to the prescribed standards and quality norms.
4. To ensure that various inputs are made
available in right quantity and at proper time.
5. To ensure that work progresses
according to the predecided plans.
Functions of Production
Planning and Control
Some of the important functions of production
planning and control are listed below:
1. Materials Function:
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 & quantity) delivery dates, variety reduction (standardisation)
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 should follow to get transformed in to finished product.
The duties include:
(a) Fixation of path of travel giving due
consideration to layout.
(b) Breaking don 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 standard times 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 be 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 Co-ordinate 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 authorises 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 centres 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 authorise 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 a logical step after
dispatching which is called “follow-up” or “Progress”. It co-ordinates
extensively to execute the production plan. Progressing function can be divided
in to three parts, i.e., follow up of materials, follow up of work in process
and follow up of assembly.
The duties include:
1. Identification of bottlenecks and
delays and interruptions because of which the production schedule may be
disrupted.
2. To devise action plans (remedies) for
correct the errors.
3 To see that production rate is in line
with schedule.
9. Inspection:
It is a measure 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 in 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 preplanning and planning will be affected by a feedback. The
success of this step depends on the communication, Data and information
gathering and analysis.
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