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Production Planning and Control

Production planning and control is a process that plans, manages, and controls resources to maximize efficiency. It includes functions like forecasting demand, product design, process planning, determining the flow of work, controlling materials and tools, assigning workloads, and scheduling production. The goals are to ensure sufficient resources are available, reduce costs, and maintain smooth production flow without interruptions.

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Kailash Kumar
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72 views5 pages

Production Planning and Control

Production planning and control is a process that plans, manages, and controls resources to maximize efficiency. It includes functions like forecasting demand, product design, process planning, determining the flow of work, controlling materials and tools, assigning workloads, and scheduling production. The goals are to ensure sufficient resources are available, reduce costs, and maintain smooth production flow without interruptions.

Uploaded by

Kailash Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Production Planning and Control

It's a pre-determined process. Production planning and control are the two strategies
that are working together in every manufacturing unit.

Production planning and control is a process that plans, manages, and controls the
allocation of human resources, raw materials, and machinery to achieve maximum
efficiency.

Definition of Production planning and


control:
Production is the transformation of raw material into finished goods. planning
looks ahead anticipates possible problems and decides in advance as to how the
production carried out in the best way.
Control makes sure that the programmed production is constantly maintained.

What is the importance of production planning and control?


• It is necessary to improve the process for better utilization of resources.
• It helps to achieve better supplier communication for raw material procurement.
• Reduce investment for inventory purposes.
• Reduce production costs by proper estimation and increase the profit margin.
• Smooth flow of product without any interruption.
• Make sure the proper quality and quantity of equipment, raw materials, etc are
available during production times, etc.
• To ensure capacity utilization is aligned with forecast demand.

Functions of Production planning and control:


A production planning and control system consists of many functions. Various functions
are as follows:
1. Forecasting,
2. Product design,
3. Process planning,
4. Routing,
5. Material control,
6. Tool control,
7. Loading,
8. scheduling, etc.

1. Forecasting:

Forecasting is the process of making predictions of future data (type, quantity,


quality, sales, etc) based on past data by analysis of trends.

Every manufacturing enterprise surviving on its ability to access, with reasonable


accuracy, the market trends survival year ahead.

Forecasters will be able to make use of sales trends, but these must be considered in
the light of the expected introduction of new materials, fashion changes, technological
changes, policies of competitors, unseasonable weather economics situations of
countries and foreign markets.

Forecasting decides how many units to produce during a specific time period to avoid
the extra cost of storage and reduces the chance of making outdated products. so, a
sales forecast should be accurate, easy to understand, and economical.
Forecasting plays an important role in product development.

2. Product Design:

Before starting to manufacture a new product or improve a product, it is essential


to design the product first.

For new and improved product design idea comes from better product planning, which
is done by R&D department.

Product design deals with both form and function. Form design takes care of the shape
of the product and functional deals with it's working.
A design department consists of designers, engineers, and draughtsmen. Making of a
new modified product will require the service of the following department of the
company.

• Research and development.

• Design.

• Manufacture.

• Account and personnel.

Click here if you want to know in detail about Product Design.

3. Process planning:

Process planning is the preparation of the detailed planning on how to


manufacture a product, thus it is necessary to plan the process.

Process planning determines the most economical way to perform an operation or


number of operations to complete the manufacture.
It takes drawing and other specifications as input, which shows what to be made and
forecast or which indicates product quantity to be manufactured.

The steps involved in process planning are:

1. Selection of process which is most economical, and sequence that satisfies


product specification.
2. Select the material which brings the right quality, and chemical composition as
per the product specification.
3. selection of jigs, Fixtures and other special attachments.
4. Selection of cutting tools and inspection gauges.
5. Making process layout which indicates every operation and the sequence in
which the operation is to be carried out.
6. Find set-up time and standard time for each and every operation.

4. Routing:
Routing lays down the flow of work in the plant. It determines what work needs to
be done, how to be done, and when to be done.

From the raw material to the finished product, routing decides the path and sequence of
operation to be performed.

In production, layout routing is not required because the equipment are laid according to
the sequence of operation. But where every time a new job is coming route sheet has to
be revised and this involves a greater amount of work and experience.

5. Material Control:

Material control is the managerial activities relating to giving instructions to ensure


maintaining adequate quality and quantity of materials for an uninterrupted
production process with the objective of minimizing material cost.

Material control includes inventory control, cost of production, planning of materials,


purchase procedure, transportation, etc.
Inventory control is restricted to the stock of desire level, whether they are raw materials,
work in progress, or finished goods with the object of minimizing the cost.

6. Tool control:

Tool control is the process of determining tool requirements, procuring new


tools, and controlling tools once they have produced.

Tool control to ensure that the right tool will be available at the time of production. Lost
time resulting from incomplete tool planning can be expensive as well as causing work
to delay.
In order to implement tool control, it is important to standardized tools within an
organization.
7. Loading:

Loading can be defined as the study of the relationship between load and capacity
of the workplace.

Loading is the assignment of work given to the labor and machinery without specifying
when the work need to be done.
The objective of the loading is to maintain an up-to-date picture of the available capacity
of the plant.
The information provided by loading is used to-

1. Ensure the efficient utilization of the plant and manpower.


2. It helps to set the delivery date.
3. To assist in future planning of the purchase of new assets.

8. Scheduling:

Scheduling means when and what sequence the job will be done.
[caption id="" align="aligncenter" width="500"] Scheduling[/caption]

Scheduling of a production system depends on external factors like customers demand,


delivery date, stock of goods already lying with retailers, etc.

Scheduling affected by internal factors like the availability of machines, equipment


capacity, availability of manpower, stock of finished goods within the plant, etc.

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