1. PRODUCTION
PLANNING AND
CONTROL

2. “The specification of the flow or sequence of operations and processes
to be followed in producing a particular manufacturing lot”- Alfred and
betty.
Routing determines what work will be done on a product or part as
well as where and how it will be done.

3. The machines are to be operated at full capacity
The product passes through those work centers which
are manned by best possible for people
 the route should be short and economical.
The person in charge should be well acquainted with
various operations.

4. “The determination of the time that should be required
to perform each operation and also the time necessary
to perform the entire series are noted making
allowance for all person concerned.”-kimball and
Kimball.
Production scheduling is the detailed planning of
materials, labour and machines time so that materials
and parts will be at the right time so that a job can be
complete within the time planned and in accordance
with the requirements.

5. Preparation of individual job schedule.
Assign “start” and “finish” dates to each of the
operation on the job schedule.
Post each schedule into the load chart.
Setting delivery date for an item.

6. REDUCING SCHEDULING
PROBLEMS
 Production simplification
 Job enlargement programme
 Sub-contracting
 Relocation of resources to suit work content
 Minimization of rush orders.
 Creating controlled work in process.
 Reducing job split ups
 Simplifying available resources

7. Despatching is the routine of setting
productive activities in motion through
the release of orders and instructions, in
accordance with previously planned
time and sequences, embodied in route
sheets and scheduled charts

8. PRINCIPLE FUNCTIONS OF
DESPATCHING
Despatches assign work to definite machines or
work places and men in order of priority and proper
sequence.
Assignment of authority.
Release of necessary orders and production forms.
The responsibility of guiding and controlling
materials and operations in processing.
Contacting the routing and scheduling sections.

9. o simple rule
o earliest due date
o first come first reserved
o Minimum slack
o Critical

10. An introduction

11. THE CONCEPT
 PLANNING: consideration of all input variables to achieve
predetermined output goals; a pre-production activity to determine
optimal production schedule, operation sequence, economic batch
quantity, etc.
 CONTROL: remedial action to prevent variance of output from
planned levels; tracking operations to ensure compliance with
planned levels

12. PRODUCTION PLANNING STAGES
Defining objectives
Setting priorities to attain objectives
Examining internal & external environments of
planned system
Determining achievable targets
Determining inputs needed to achieve targets

13. OBJECTIVES of PPC
• Effectiveness: goods to fulfill customer’s needs
• Maximizing output: maximum output with minimum input
• Quality control: Product/service quality meets planned quality specifications
• Minimize the time: conversion of RM to FG in minimum time
• Capacity: plan for current & future needs
• Reduce bottlenecks: solve production problems early
• Maximize profit: minimize cost
• Production schedules: as per plan
• Routes & schedules: to optimize use of men, material & machinery
• Maintain performance: maintain standards

14. FUNCTIONS OF PRODUCTION PLANNING
 Product selection & design
 Process selection & planning
 Facility location
 Facility layout & materials handling
 Capacity planning
 Systems & procedures
 Estimating quantity/costs of
production, men
 Routing operation sequence
 Job scheduling & loading

15. FUNCTIONS OF
PRODUCTION CONTROL
 Inventory control: MRP; JIT
 Quality control
 Maintenance & Replacement
 Cost reduction & cost control
 Dispatch / Despatch
 Expediting/Follow-up/Progressing

16. SCOPE OF PRODUCTION
PLANNING & CONTROL
 Material: RM, components, spares, right quantity, right time
 Methods
 Machines & equipments
 Manpower
 Routing
 Estimating
 Loading & scheduling

17.  Planning: Pre-planning – product planning & development; demand
forecasting; resource planning; facilities planning; plant location & layout.
 Active planning – quantity planning; product mix; routing; scheduling;
material planning; process planning; capacity planning; tool planning.
Action phase: execution – dispatching; progress function
Control phase; status reporting; material control; tool control;
inventory control; quality control; labour output control; cost control

18. BENEFITS OF PRODUCTION
PLANNING & CONTROL
• Better resource utilization
• Reduced inventory
• Reduced manufacturing cycle time
• Higher quality and lower production cost
• Faster delivery and better customer service
• Lower capital investment
• Improved sales turnover
• Improved market share and profitability
• Competitive advantage
• Flexibility
• Dependability
• Lower prices

19. LIMITATIONS OF PRODUCTION PLANNING &
CONTROL
 Based on assumptions
 Resistance to change
 Time consuming
 Difficult due to rapid environment changes

20. REQUIREMENTS FOR EFFECTIVE
PRODUCTION PLANNING & CONTROL
 Sound organizational structure
 Delegation of authority
 Reliable, up-to-date feedback
 Standardization
 Trained people
 Flexibility to adapt
 Appropriate management policies
 Accurate assessment of manufacturing/procurement lead times
 Adequate plant capacity