Chapter 5

• Production Planning and Control


  A tool available to the management to achieve stated objectives. It encompasses the four factors of quantity, quality, cost and time.
• Production Planning


  Analysis of the given data like demand, delivery schedule
• Production Planning


  Pre-production activity to predetermine manufacturing requirements like manpower, materials, machines and manufacturing process
• Operation Planning and Scheduling System


  Concerns with the volume and timing of outputs, the utilization of operations capacity at desired levels for competitiveness
• Shop Floor Control


  Involves the activities that execute and control shop operations namely loading, sequencing, detailed scheduling and expediting jobs in production
• In any business organization, profit is the ultimate goal. To achieve this, there are several approaches.
• Production System

  is encompassed by the four factors i.e quantity, quality, cost and time.
• Production control

  comes into action if there is any deviation between the actual and planned
• Corrective Action

  is taken so as to achieve the targets set as per plan by using control techniques
• Need for production planning and control

  the present techno-economic scenario of India emphasizes on competitiveness in manufacturing
• Production Control

  Inspite of planning to the minute details, most of the time it is not possible to achieve production 100% as per the plan
• Production Control

  through control mechanism tries to take corrective action to match the planned and actual production
• Planning Phase

  is an exercise of intelligent anticipation in order to establish how an objective can be achieved or a need to fulfilled in circumstances, which are invariably restrictive.
• Prior Planning

  means pre-production planning
• Active planning

  are process planning and routing materials planning
• Action Phase

  major steps of dispatching
• Dispatching

  is the transition from planning phase to action phase
• Progress reporting

  the data regarding what is happening with the job collected
• Corrective Action

  make provision for an unexpected event
• Pre-planning function

  a macro level planning and deals with analysis of data
• Planning function

  starts once the task to be accomplished is specified
• Business Plan

  statement of the organisation's overall level of business activity
• Product groups

  a set of individual products that share or consume common blocks of capacity in the manufacturing process
• Aggregate Production (output) planning

  process of determining output levels of production groups
• Aggregate Capacity Planning

  process of testing the feasibility of aggregate output plans
• Master production scheduling

  schedule showing week by week how many of each product must be produced according to customers orders and demand forecast
• Resource Requirement Planning

  process of testing the feasibility of master production schedule in terms of capacity
• Material Requirement Planning

  system of planning and scheduling the tome phased material requirements for releasing materials and receiving materials that enable the master production schedule to be implemented
• Capacity Requirement Planning

  is an iterative process of modifying the MPS or planned resources to make capacity consistent with the production schedule
• Loading

  each job may have its unique product specification and hence it is unique throughout varios work centres in the facility
• Sequencing

  this stage establishes the priorities for jobs in the queues at the work centres
• Detailed Scheduling

  determines start times, finish times, and work assignments for all jobs at each work centre
• Expediting

  a proces of tracking a job's progress and taking special actions to move it through the facility
• Input/Output Control

  related to the activities to monitor actual versus planned utilization