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UNIT
INTRODUCTION
SIA GROUP
RARTA
a1. Define PPC. What ae its oblectlves?
OR
Define Productton Planning and Control. Model Paper-4 aa)|Apr14, 1 , 01AD
oral.PRCN
OR
Define PPC Apriy-1 &e2 01
OR
What are the objectives of PPC Aprilay-17, S QYN
Reermb Toplsberte ofPeC!
OR
Ust the objectiye of planning and control
Answer Apriay 1,&eN
Productioa Planning and Contrel (PPC)
Production planning and control may be defined as the coodinatioa af the senes of functions acconting to a plan which
will ccooomically utilize the plant acilities and regulate the
orderly mavement of goods duriag the calire manufacnuring cycle,
rom the procurement of all materials to the shipping of finished goods at a predetemmined rale".
-
Charler A Koepke
Objectives of PPC
Tbe following are the objectives of PPC,
To artain the highest degree of customer satisaction and least cost by delivering the goads in the needed quantity to the
customet al the roquired delivery schodule.
2. To make optimum utilization of rsources.
3 To sure that the quality
products are produced.
To sustain the optimum level of iaventory
To rustin the lexibility in
manufscturing operalions
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 UNTUKAKNADAJ
ONTTION PLANNENG AND CONTROL behween Job Order Production and Batch Producte
gs Lst out the dterences

coedasia into tao ypa ADser

Padecion systs
Production System can be diferentisted as foDaws
Job Ordar Prodoction and Batch

This prodacin sysa vohes aa tateapted low SN

Job Order Productioa Bateh Preia
af a a l drsugh de phnt Interminent productioa i Stundardmechineries are instled depending on whetherSpecial purpose mechimeries a
the factory is engaged in lighl, medium or heavy
engineering
ShopProderti Syv
Bac Foductina Sysaen Similar machines are armnged. Different mechioes may be grouped
Cet Priecsn Syut Cast amd time required to make product will be high. Operation time and total time to mae
pd
Tt r a b i syn ivehes contiacs or almos
satisfoctory
s espa d s co s pysieal Bow ofeaal Cootiaous prohrtion is 4. Work in progres will be high. Similar to job production.
5. Requires standard material hamdling equipment. Requires special purpose handfing equipme
(e) Ms Pradation Sysem
6. Requirs peal supevision. Similar to joth production.

n g =dtidta
Flo Pradactisi Syslem 7. Examptes:Ship building, civil engineering etc. Exampes: Machine tools, funinre, pharmaces
C4. r i s a note on,
Q6. What are the applcations and xamples of batch
(a) Job order producton. shop production.
Answer
s e A l s e p i a yon s a d d b y FPC D)Betch produetion Applleaftoas of Rsteh Shop Produrton
ehed Seeciza OR
Balch production isepplied ia either ofhe Tollowing situations,
FRCs a d e i c t s f e e d of pdim What is job order production? 7,L When quatity of output increases leading to
repetitiveness
c3. h s oradton sytem? List o t ratou Wheo there are fuctustiens in market demand
acros the year.
produen systes. OR
Batch production systerm is commooly followed in bakeries and in
OR What ts Bateh Produetion?
products ec menufscturing of sport shoes, paints, phs
Whet
5ysens
are the variaus types of productlon TReOaly TpEkaEh FR3Eron Ermpls of Batch Sbop Produrtton
AUA|A A,UAnsai
SoDe of the cxnples of batch production are p1ints, elothes, drugs, sheet metal pressers, forging machines
(o) Job Order Prodortlon a7. What is mase production
OR
system? Wrtte ts applieations end examples.
Job order production is also known as jab shop OR
List out diTerent types of Produetton production. The job shop productioo system deais with Write the appllcattons and exemples for mass produetion.
r i ) ta1 o|produeing the products sor ful6ling the customer needs o
R Dalr Topic. Tpof Producilo Syem requirmemts. Io this system, all the order eed different
OR
processes and differeni sequences of techrologieal order. Amswer Ap1L
(b) Bateh Produtlos Mass Produetion System
What is continuous
produetlon?
la this type
EOHl Topte Controns ProdacHon byslem are
of production, two or more types ofproducts
maufactured in lols (i.e, batches) t reguhr Intervau. production e n t parts or assemblies are manufactured with the help
ofa continuous proces, then it is known as

Anrer
A , L01t Diferem products are manufectured nd rtacked and then sod Applleations of Mass Prod actdon System
Produrfioa Sysiem on receipt of orders.
e concept of mass production b arplicablE to different types offuids gnd particdlates handied in bulk quantity
A
pmductim syslerm converts some inputs lke men,
materel, roey er mto usefol outpuls like fnished products It
This is generally
the suge in
adopted in medium size crterprises. n e d minens and chemicals) discrete solid parts (like fastenes)
and household applianca).
to to sssemblis of those parts (like automot

ad servce. Thetransormatian of enput mto outpt is achieved 1t

is
between job production and mass production.
is bigger in scale than the Exple of Mas Prodaction System
through d produrtion sysiem. job production while it is maller
than that of mass
production. Components of industrial products.
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 PRODUCTION PLANNING AND CONTROL TJNT AKINADA UNITT Inuouuguon
T o artaio tho highest dagre of cusloper satisactioa nd leaad cou by dallvaring the gouds la the nseded
PARI-B quomer at the required dolivecy sahedule, quadly to
To make optimum utilnion of neoureed
To aure that the quality producta are produce
To uatain the optknun Irvel of inveniar
a8. Define productdon. ONscuas about producton planning and control
To urtain the dealbitity in manuhchurng oparalona
OR
To make sure thal there is eddetivo redunlea of a l nd coul Gonurel.
What PPC? Whatla the need for PPC?
Tb ure eMbolve renult (or least uotal oorta
Th prevent and atop the barriere of tagea of produotioa
OR
Td solve the productioo problema
Explain the importance of PPC departmant in a typleal produatlon eyutem. 0. To increase the ooordinetioa berwen duTarcal departroent, labour end machines
To inereae the profit levela ofthe tim
Anower
12. To retain the mabiliy in produuion ayutaun
Producto 1. To maks oare that uhe demand le forecased ia praper manaer
Production Lavalves a senes pfoperatioas which canveart the mairials bom a given fom to a deaired fara
Productloa Plaaaing and Caatrol (PPC)
1 Toohectlvalycamy ou theoplimumutillatlon ofinvenioy
a10. "Producttonplanning and productton aaptrel anre the hwo baale funetlona of PPC" Brplel
Prodcion plaanung anad coaurol may be dañoed as tbe coordinatiogn of tho series of functions ascordingtoaplaa which
wll conomically uilize the plant faciböes and egulats the ordery movemealof goode during tha entird maaulcnariag yole
OR
Deine Productlan Plannlng qule ke obeatvee. Liot the indormaton requed for produotlon plennne
iram the procuremeni of all maerials to the ahipping af finabed goois at a preada terninad nie" - ChurlesAKopte
Productioa plaaniag anul caatrol comprae the planning, routing achecduliag, diapaucbing and folow wp uactionsiathe
and oparutdons of labour bowev OR
roducuve process, so organized hal he movemeni of malerial, performunce of machines
ubdinded are direcied aod coordinated aso quantity, qualiy, lume und place. It ia basoad on the priaeiple "plaa your work aad Dlecuss the objeottves of produatlon çontrel
work your plan".
-4ordand Beary OR
Productioa planaing and conirol ia the foremos setivity af productioo process wbereia firms make dociaiona regarddang
be maienals and payaical aciliies so as to optimally achieve the pre-deterenined objactivea. It lavolves tha planniag, alocallag
DNacusa the oblectlvee of productlen planning
nd coordmaung aciviis.
mpartaace/Need for PPC AMwer
The umporance or need for produstion plaaning and conarol caa be made clear throvgh the following poiois, The two basic fnctiog of PPC ar
. Production planniog and
Produciioa planning and coatrel belpa in plannang purchase ofmw materiala,
compoocni parts ete, itennures thattheright
quannny of raw maicral is brough a the righi time, at nighu place, frocn the right sourte and a righi (reasooable) prica. 2 Prolaaion onnarel.
belpa in sctuing performance slandardsfor employoes as well as equipaneats Productlee Planang be mase
and ooerallag the enbads lo d
to
It makes sure thal the resources available n the organizaion are utilied to their optimum level. coscerned with planaiag, diretng
Procductioa planaing ia the Aunctioa e l ahouhd be lalkd eul a s
cilies bulklags, machie equalpneel
lAumS aL maufecnuring qualiy producy withn the budgected cost and time the way in which tbe production
prodacls and
avallable for productioa"
Routing. scbeduling and dispaching are the imporuant funciions of production planning and coatrol,
PPC proces inyolves regular inapectioas and tbese inspectiona enbanca the performance kvel of workans, machloen and yeke
gpalle aowre afastien or produeten
prucese Prouctdon Planning u concerned with doveloptng
lt belps in selecting one best propesing technique from lhe number of atarnative iachauques
ensures Aexibulity in producuon related oparnalions.
obJetves of Productea Phaalag planaing,
9. Explaln the objecuvee of production planning and control
Pollowing are BOme ofthe objecuve of producuon
OR sush pa m a marl,
anacbinea, aar ete
T eveuta the nature ofraouroes kungn.
What are the objectives for whieh PPC department le establahed in a thclory ayewm t g ia deubd il theprodben
to aahieve the produstion
Make
necemao,anmAgemaps ew madala, beman
d odlar ap
me ar eoovertáng roerpe A
imah operating
The Collowng are the objetivea of PPC, produt eelenty" ROUP
Aa ROn tha TonLEcOVeR Dor vou tuv
 *N ANDCON
Iaformetlon Nerded for Productlon Plnaimz Routing | (e) Evaluating and Cor
Metbed Seleetes
reethve Actea
mehod Iis the process of deciding the order of operations to The entire process
The following information is needed for prodhartion PPC hels in the selectiom ofbest
roin many other avallable altermstives.
ofproducton be carried out during the production proeess. It ascertsins asto the necessary imrovemerts
ofmamu [nctrirgi
planning wherever they s
what work should be camied ou? How these cperations will be
Tnspection Control of varfous
() Theresourshalacuselul forproductionachslabor,
mateml cc
parformed And where these operatiors would be performed? activts lie n
analysis, inventosy control optimaleplo
and
PPC communicales with quality deparnment and ' s main objective is lhe selection of best and cheapest way to

Demand forecassing in prospet

formulates a plan for comtimuous inspection across production perfom a job s0as to reduce manufecturing cost
of plaring process. 013. ExpBaln the
(ii) t eeds muborized subconirecting quamity ad back Preces Plaas
() Sehedeing
Plannig' and relationshp betveen
order tevel. "Comrol" ofetUgua
producton plennlng and produet
PPC helps in ascertaining the best kequeree ofoperetions It
includes giving priorities
to diferet
jobs and
asoertainig the starting and firishing time of each operation
(iv) Siarníng and neceay endíng inventony. and in planning lor ligs, tools and fixhres. i sets esential OR
ectivity. Seheduling basically lsys dawn the preparation of time
standards For the establiahment of time sehedules for diferem
Prodeetton Control based schedule, which shows the lime and rste of production. Explaln
stags of production. th
reladomhip betwoen
Plenning' and Control
Produetion eontrol refers to the varioustocontrol| 12FUNGTONTANDT AsES OF PG (d) Ladine
techaiques sed to schieve pefosmnce according the e R Ony Topie ReIbrasi
plans Produaiom conuol coordinales diferent resorces. It aimsa12 Define the functioe of production plenning nd Machine louding is peformed along wh rouning to Planing and CorroD
ai behicving produrim tergels, îETeased profra, opimum use conbol. nisure the mooth workfaw while fixing the lods to difTereot
of avaiable resources, betier qality and more ereromie goods. macines, jobs pnony nd machide capacitues are considered. OR
R
The produaian of
eontrol regulales and controls the dilferent List out the planning funetions and controMao
Schedulingenables the fm to be aware ofthe delivery dates for
the production ofparts, sub-assemblie and finished produrts. It DHterentats between Producton a
taskoperalios produrtion pros r orderdy and smootb productlon control.
msterial Nov functlons *parately, explain them briemy. is also used to maintain umiform loed on different wark centers
and machines.
ObJectlves of Productdos Control , a
Plonining 'and Piodectfon Conrol
OR e) SeqencinE
The objectives of production control are,
Expleln the functioms of produeton plannln Sequencing involves the determination of the arder in Arawer
To optimize the use of productian resouTces. and control.
ich the operatiowjobsme processod. Problems may ariseRelatonship between Produetlan, Plennlag e o
he work cenresare heavily loaded and the jobs are lenghy.
To develop contenmporary standards of production. Answer Thercfore, processing the arder is very important with respect The retetionship betweem Production, P
The variou fmctionsofproduetion plaenningand control control' can be understocd from the following
f
3 Tocrureaccurateproduction cosi conmtrois. to idie time cost and aiting cost
ure broadly categorized into two groups, es presented in the
011.
Write about the scope of production panning following ngure
ond control.
Produrtlon Control Fanctions
LProduction Plarnimgd Control The following are the production cantol fmctiors,
Ansva

The scope of PPC can be understood frum following ( Dispatehing Propctian Syuten Proin
Me Conrol
poini Production Planning on Cob t is related to the actuml performarjce of work
through Mtou
Eaftog Dispatching planning process wheTe the Instruetias are delivered as per
Merket Foreeasiin Mechins
the schedule,
b. Routin3 b. peditingFollowup seqeTIces shown in the roue shees end mBcime
PPC communicaies i t marketing desrimem to find Scbulmg Progenn loading schedules. Based on Their +nsrTwation, ordera of raw E
sut Ue product's magnitude and dellvery details. 1 Losding Iopection materials can be dispetched 1o te desired site. EnforTion Comp
dEahating aad coeciy
Matertal Pianmlsg eSesuemcing tion d) ExpeditiegProgresing
PTC makes a contact with purchase department for Keeping track on the productiom activitiea fct easuring p
precurement of input in an eficient mnnner. It plas the Fetkmo PPC that he activities a e performed as per he schedule is knowm Coods

procurement of spare parls and raw materials in the rightProdaefion Plannlng Faactions expediting. It follows dispatching funetian. Sovics
quantity, at the righ1 time. from the right source und al the right The ollowing are the main funetions of production
(c) Follow-up Fiore eateahig Brtwem Prelrtden Plendag ed
place. planning.
3. Homan Resourre Tiannlng Etimaioe Followup is oue of the stage of ppoduction contbol which Produetio is defioed asproces by whid
Tvolves the comversion of pans imto actions. or services afe produced. It is a way of converti
PPC comtacis HR department and forraulates a pan for Estimating includes tuking up the decislons aboút the stertals inlo finisbed product by e e i n g out sreci
HR Pannimg end welare ofjabours. quantity ot goods which e to be produced and the level of (d) Inspectton menufacturing opeations.
cost in produeimg a produt on the basis of saies forecast.
Layout Plannlog
I inchudes aucertaining the perTIonal capacity af the
Tt
constiutes checking the quality of production proces While panning iînvolves preparation of
PPC Provides the iprts based ao whieh he plant layot
machive and materials required, in orda to meet the larget of ing theefTectivenesofprocess, methods and workers. So advance before thestar of actualworo
19 made Alzo the plat Iayoun is esecuted by PPC. tat desired quality can be achieved by making the necessary supervision o f alt ihe imporsot a p e r a r
planned pTOduction be>ore the budgeting is done for sourea
mprovemeals tn the process. mechanism thal provides the rerdback of wark prog
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1 RODGGON PLANNING AND CONTROL 1JNTU-KAKINADA UNT;1 nlroducion 1.9
befween rrdacoon ranaing and P'nductien Control v) Tme Tieket
Dilferraces
The daleeacs benwe production plaaning and produclion conurol are as follows, Tune ickebaard oicial which reconds the time takea to compete the varous proccsss
Praduction Planning Laspecties Order
Freductlon Cantrol
Under prodaia planning. the infórmaion relating to .Uader production coourol, the data is provided to differen As the name indicates, hrough uhis oficial insanucias ere
givea lor inspocting and iesing he vanous processs of
i i e r esseatial inpus is colecied and maintained prodaction lastrucions mast be followed by thbe various departmenls lar minimizing the cost averbeads off rewor
lt involves tbe preparalion of paper work und ouher
productiom sections
t invalves the isnue and accmal use af paper work and ()Meve Order.
e s r y lorms. tocms Ii belps in moving tbe nw malerial, componenls,
spares, sub-asemblies towards he productioa sile. Tbe umely movena
s aalzs atviy and is caried out in oiñce. Iu 3. Productionconurol is a difiuued aciviy. It is carried ou ol malcrias belps in overcoming the delays in
procesiung, thercby asnng the quick falAllment ol ordes.
incians nclude procs planning job schednling aod a shop foor Is funcions include expedining progessing Coatrel Phase
aieras ptannen and dispalching In this
pbase, oecessary guidelines
are
provided o the producion manager o the form of eedback whach
elcctve conkrol of productian activiies. lt cociains two major activitia,
belp ia the
Renedial actioats take wbeacverthercis afaiure |Remedial cion istakam o modifythe faikure
a14. Hhat are the phases/sages of PPC7 Explain.
Pegras Repartia
OR In this nubphase, data related to the aurenl a n s
of work deacmiod which can be coapared with the pre-sd sundards.
is

Dascribe the activites in folow up or control phase of PPC. A-7,22) The data
relaled to maerial rjctico process varaions, equipmenl ilures, operator eficieny, operaiar abseniceism s
oa are collected and nalyzed through variance analysis. Sach anayais is used
seOnz Tpis Carzol Phae) to be comaled by taking correcive actions.
to recognízz the aritial s a s which nccd
OR
What are tha aclvites in control phase of PPC? Explain In briaf. ) Careetdve Actes
Carrecive acoas are mosly suddea and situational and leko the problems cacounieredn paring
Reler CnmbyTepis Canspl Phazet proess. I includes the following acivises,
ae lo overcome

Asser
Following arr thee sagesphases involved in PPC. Creaag Schedule Peiblty
Placang phase Becsuse af same ncapecied rasons if the pre-planned schedule is
to make the chedule ieible.
col cmea, then some adjustm.ents ecd o be made

Actiaa pase and

. Cantrol phase. ()CapscdiyModiscate
bas be
Pianning Phase Capaciy to modisied depending upou the demand. 1f tbese e s s variasion in demand thea the capaciry ba
to be changed basod an the variations
Proiuctn plennng s tbe irs phase af PPC, n whach firms are inyolvedn Sorecastung the appropriaie actins thraugh (u Make er Buy Deciules
whach tbe sed obyecivesaerh1eved In this pbase, pruducuon needs are deiermincd along withthesequenceofoperatig,
EUQ, desaicbng pnoriis and so an. Placningu sscenal for caryung our all the produetioo acivitus in a smooth manoet. when the decsioas related to "Make or Buy" of a product are ailed thea they sbould be re-aanned amd proper
decisioa whcb is mast ppropriste for firms should be made.
Maming phase includes wo ypes of plaanmg&
Priar Planaing
( ) Epedidag the War
|Pre-producloa Pian
lh nciades
al the anempus done before the iniuaboo of acuve plann1ng like product development and design lorecasting Wbenever the resuhs of dhe progress repon are not in accordance with the set tages, then sppmprate acions should
be taken
g a l e plam1ng, master scbeduliag, order wriung, MRP and so n
(1) Acive
Plaaniag lActual Preducioe Plaaniap] Replaaalng
efaely follows the pror planning end includes althose tasks which anre directly relaled tothe procesofproducion. Irthe cspediting u (ailed to brng back the desired resuls as per the suandards, hn tbe enure phaaning proces sbondd
be redesigned
S elaed to process plannung and roting, malerials planmung, iools planaing, loading and scbedalíng ure made in
this type of QScbedalin (0 Dispamchiap
planning Prodact desin and
Maueria
Artion Phae developme
Process desi Mesbod
wach ircludes scruçial
afallow
a
up suage ofplanaing phase. in this acnual mamuíacruring af the produc compoaent is initiated
step of dispalching
or a
Sales forecasting CEsimatin I. Lnapectio
Warkeare desiga g. Machin
chng
producia. saakes
procss af unaslemng the maenals otber productional resourees for their conversioa
or into finished Fsctory layout
Dipaichung pace through the job arder, order, tool order, lime
siore issue
uçkea
iaspectuoa arder nd order. move Tochnology adaptation 4. Men
) Jcb Order Equipmat selecion
Change in capecity Kaowledg. 12. Epedining
sthe crucal mmber
speiically aloued to ach liem nds valid m all Pre-planning production
and follow
Stare lssue Order
other repors/orders. G. Lnlormaticn (7. Rouing
places thbe order wnth stors to 1sue the specihed maierial thal r e requred for manuachu mg thai product according top
he praduc specricauors. 13. Evaluai
( Toal Order PTeplaaning Coatral
Based aa dhe tool arde, the twol room provndes the requred tools nacessary for the smooth funcioning of he process. Figare PPC Cele
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PROOUCTOR
a16. Lst out the adveniagee and dhadvantages of PPC
1.3 EMNTS OF PRoDUCTION cONTROt OR

015. Expialn vardoue elements of production conto. Diseuss the benefts of producilon ptanning and control.
OR
of productton control in detaln OR
Whet about eements
Stete acventages of better produetion planning and control.
OR
Discur ebout direent elemeis of PPC. Top ABiaga7PPO
A 7 , SA
Advantege of PPC
T Vaoas elenara of prodecton cocrol r e
The edvanages of PPC ae s follows,
Control of matrvials Productiom planning and control is one of the
Conto of plarin most tmportint functions ofbperations
he hean of operations management which co-ord inats managerment and is c o
differeni of
stages production.
( ) Cagol af mamufacturing epeciyy Effective and eficient production planning and
control leads optimum utilization of resourees, best
to qai
v) Coool of tookn manufecturing cycle lime, loweT mvenioniS, quiek and easy delivey, lesser production costs, lesser amoun of
irvestment, beter cusomer svice and geter customet xtisfaction.
Comro ofqasntity
3. With the efficiei utilization of resourca n
(i)Ctral ef nciities lesds to increase in productivity and economical
qonlity ofgoods with right cost1 would resil in i g a customer stisfection. production on time
v i Comrat of dae date
. Smooth fmetioning and proper arork-flow em be the
(vri Com of materal badling and ensured
breakdowns. This would furha reduce 0he idle time of with machineryplant facilities when there are les mumber
of mad
und discipline by an employre.
laboar, and equipments. Thus
increasing the
()Coned d mfomalsn
( Cotrod of Bimerta Productive PPC helps the fim to increase its total retans, market share,
profítabiliry.
I o r ono of vermery. i provdes the inferanicn for isse
of malerials to the shop and abo the moveme It helps the fim to fece the competition by mintaining stable imventory levels, best
qaliy. stability and reliabiay
of matenals wrthro e shopP reasonable or alTordable prices
Control of Pueang Disadvantsge bf PPC
The disadvantages of PPC are s folows,
(a) Reer of l e a f o r a dsta from als d pmduction plaing he etmptions end forassmade in production planning and eomtrol may not be accurade sometimes. Wrong aumptio
) R o n g inlermation fom proees e a i n gand egarding avaitability ofrawmaterials, stemers demand and plant and equipment capacity lead to wrong resulsof PPa
Routing and scheduling ofbig and complicated produrts ise difñcult task and invove lot of ime
(c)D af material data from pnduci enginerng in production evels besed on production
plars may not be acceped bry employes
.
( Coetrol of MasefacturlsE Capaclty
.
Ftoctuaticns
Eeciive production planning nd cotrol is not possible in cireumstances where frequent changes takes place in
n fimds the vaibb iy
of recordng complad poduction
ofluboa md equipememapacities nd isoes reafiie prodoaction schedidles. It also provndes meas environment Like changes in ecutomer taste preferences and habits, changes in government roles and rgulatic

(l) Control of Toollng

tectnologicsl chnges,inadequate powersupply, ucertain natural problemslike, war,esrthquakes and soo.
1.4 TVPES OF PRODuCTION
l arvolves. checking the toling availabiliy and isming of teols (rom tool eribs to the shop deperments. 017. What do you underetand by a production syetem? What are lts varlous types? Explain functionsg
Control of Quantity producton sysem.
This involves follew up of progress of production, so as to eemre than the requiredqunmnies are prócessed al each siep. OR
Also to t s e ha corective action is inniated uhere wnk (ans to raas ach inspeclion stagge Descrlbe the ditferenttypes of produetion system. Aor t, z

( Costral ofAcivils
RTE Onls opt Tz oProchrcilon SylenT
It ivalves, release of mfrnnin a d ordr t asigned time OR
(vD Coatral of Dae Date Namethe valos types of production system. Describe the production system sutable for job wor
mwrodre, cherkig the relmion of ecraal snd plarned schedale and find the cmse
schedaling of wak azriged to evey macbine
ofdeley that interféres with weckly
OR
(v) Control of BMaterial Handag Expisin nrious types of productlon oystem wtth examples n141,
It mchudes, reesing ardera lor mevemers of work ta ecere availability ofmaterial es needed ai every stage ofoperatiom.
) Con trel of Infermatiom OR
ivabves. disribusting tmelyreports and
information showing deviations from plan such thmt comedioe action can be Expan about functions of production system
telen. Aleo fer fature plarning dms
providing productiom performance meruremen
om

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 1.13
wer Cantinuous production ls classifiçd as,
ductdoa Syslem L Mass Producion System
Apraductian syuem convertss0meinpus likemen, materal, mooey cic, iato uselul ourpus like finisbed products and IL Flow Producuon Systen.
a Îhe transíormaion of npul aio outputsisaLchieved through the producuon syslcm. A typical productiaa sysem is sbowa
(a) Mas Productdea Systemn
e igure
When diferent parta or asemblies are numufactured
with the
producion. In this type of production, machunes are organized belp
Deparunents as internal ofa coatinuous process, then d is known as mass
Customer (TQM concept) in the form of a line or
very lurge yolume of productíon. Mass producioo includes both producl and product layout and il ovolves a
Men followed by all ourpuls. procesS standardizaluon and similar palh is
Gooas
Machinc Customer Example: Composenis af Indusirial Products.
(b) Flew Prodactlon System
Tecbnoiogg Inform exterual
Transfamation aton Flow production system deals with continuous
Finance physical flow of materials It is used when the product has last cansumpton
raie and has
process continuous demand.
Dala
Service Exmples: Pekrol, Cberuicals and autamobile planis.
Functlons of Productlon Systems
The production system is broadly classiied into iwa
types,
Feedback Customer Respcnse After sales . Intamitent Producton System
and conrol Production system
servces
Intermitent production sysem is sub-classifled inio two,
) Job shop production system and
Flgure Praductiea Syutam
() Bachproductionsysten.
pes of Production System
Production system can be classißed unto wotypes,
Functions of job shop pmduction systerm and batch praduction system
arc as follows,

(a) Job
shop production syslem deals with panuíachuring the products for fuliling
Production System customer
the needs and requisemesis of

(b) Baich production system deals with manufacturing two or more products in bauches il regular intervals.
IntermEnt Conliauous
Contünuous Productlon System
Production System Production Sysiem Continuous production system is sub-classified inio two,
() Mass production sysem and
lob shop Produrtion System -Mass Production System
(i) Flow production system
-Batch Productioa Sysem LFlow Production System
The functiama af mass producion system and flow productian syslem art as follows,
latermltteat Productlon System
()Mass productúon syutem deals with nunufacnuring difereni parts or assemblies through a coniuous proces,
"lnicniteni poductioo" involves an intemupud Aow of maleral through the plan. In this productioa system, geoeral
pose machines are used. It produces the items which are dilfererl n nature and in small quantities. (b) Flow produciionsystem deals with producuion of productus with contunuDus pbysical flaw of malenals.
018. Liet out the chanctoristies of dlfierenttypes of production syatems.
lniermitieni prouduction is classified as,
Anwer
(a) Job shop production system and
1. Characterstics of dob Shop Production Sytem
(6) Batch production sysiem.
The main characteristics ofjob shop production systGm are as follows,
)Job Shop Producisoa System
( Small Productlon Runs
be job ahop production system deals wih produciag the prodcis for fulfilling tbe customer necds ar requirements. la manufactTures one or fcw number of single designed product surictly according to customer's speciicaboa
hs sysem, all the orders need different processes and different sequences of technological order. The main objective of
ahop production sysiem is to fulfll (U) Flow of Materlals
Job therequirements ofcustomer's orders. due to unbaiencc
Ezample: Tailor's sbop, vehicles repair shops and other small worksbops. There
is highly discontinuous flow of materials and components at different slages of produclion
opernion-wise work conteat.
Batch Productlon System
(1) Maaufacturiag Cyche Tlme
thu ype of producion, two or more types of products are manufactured in lous (i.e., batches) at rogular intervals, as maleral procesng 1uges
ETEnproducis are masufacured and suacked and then sold oa rcceipt ofordea. be
manuiachuring cycle time is lengthened due to lang dolays al assembly as well
s8 r ingcoenly in medium size enterprises. It is the stage between
adopted in und aass production. It is
job produclian (iv) Layout of Plagl and Pquipment,
scale than the job production while it is smaller than thal of mass production. and sequenoes rom produict lo
roceype layoul ls used in these productipn systems as there are changes in operalions
Eample: Dnugs. paints, cloues, forging machines, sbeet metal presses. product
2
Contiawous Productioa System () Cost of Production
a
buying
of production because the firm cannot uke advanage large scale
of
uous production sysiem unvolveaa continuaus almost continuous or physical iow of maierial. This productioa hgre high cost involved per unil
machunea. in rge quantiues. automation
pecal paapose lu produces the slanuardized compoocnts
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 UNT-1 Introducton
JNTU-KAKINADA] and machinery
of investment in equipments
PRODUCTiON PLANNING
AND CONTROL . t requires small
amaunt

can be stated early.

1.14 2. t is flexible in nahare and
of Bateh
Production System
defect in one operation, does not iterrupt the whole pröcesa,
Charactertla

are as follows 3. IntheJob ahop system, amistake or

of batch production system the chances of failure are also less.
The characteristics
4. The risk involved is less and
Predactdon la Betehes
crdeT procured.
Dbadvantares of Job Shop
Produetion System
manufacturrd in batehes s per the specific
Anicles re
disadvanta
ges,
Divislon of Labour
Jobsbop system has the following
( is very complicated.
Division of lsbour is possible. The produetion syslem ofjob shop system

Flow of Materials The job shop system faces dificulry

in lading the machines
( intermitent. It recquires high inventories.
Flow of materials is
in job shop system is high.
( ) Pleat Layout The eost ofraeterial handling invofved
Plant Layot is of procss p e Advantages of Bateh Produetion System
(v)Maintenanre Batch production has the folfowing advantages,
is essential
of machinery md equipmernt
Proper maintenance Plant and machinery are optimally utilized.
3. Chernrteristies of Mass Prodaetlon System When compared to job arder production, cosi per unit in batch production is less.
system area follows,
The characteristics of mass production in batch production, investment in plant and machinery is aso low.
Prodoetion la Larze Volumes Butch production is flexible in nature to follow any process and mumber of products.
Production is camied out in lange volumes.
sstisfaction.
an Short Cyele Time
. Operators enjoy greaterjob
Disadvaatares of Batch Produetion System
The cyele time of produetion is short
Follawing are the disadvantsges of batch productiom,
(H1) Mechiaes and Equlpments
and autput rates.
which have the higher production capacties Due to inegular and longer lows, material handing is dimeult
Special purpose machines ere used
2 Production plerning and control is also complicated in batch produetion.
( Flow of Material
eny backward repetiive modificatiocs in set up. it results irn higher set up costs.
movement
flow without Due to
Malerials, components and purt have contimuous 3.
4. Work in process inventory is higher when compared to continuous roduction.
(vil) Material Handling
'
Material handling is cried out auiomatically. Advanbuges of CoatinuousFlow Prodatton Syatem
4. Characterlsties of Flow Production System Following are the advanteges of fow production system,
the characteristies of low production system,
In continuous production system, the production planing and control is simple when compared to job ar batch pro
The following are

(Flow of Material t makes use of speialized machioes and procedures for standardizing the items in large quantities.
he rocess.
In the fow production system, the products pass through canbe used for mamuhe
same

Truhe management takes the decisiom Sor discontinuing particular line, then same machinery
a

(a Material Hndllag other anlele.

Aow production system. Material handling is minimized.
Handling of material 1s done aufomatically in
( ) Plant Layout 5. It helps in providing lowest production cost per uniL
The layout ofthe plant is designed on the basis of production requirements. Disadvantages af Continuous/Flow Produetion System
(iv) Control Metheds The following are tbe disadvantages of continuous production system,

Sophisticated comtrol methods are used for measuring and controlling the inputs and outpots. 1. The effective working of contimuaus produstion sysiems depends on effective plarnt maintenance and effeti
(vMaintenawce control

Proper maintenance of plantsand effectivecantrolofquality are the pre-recquisites offow prodhuction system. 2 In contimus probaction system, he managers have to pend significant efores for the plarening before saurtng
the
of dimerent productlon aystems. As comtimuous prodvctiom system makes use of specialized machines, the amount of investment spent onthee
a19. Llst out the acvantages and disadvantages
is very high
Answer
Advmtages of Job Shop Productlen System V Advantages of Mas Prodactlon System
1
The following are the advantages orjob-shop-production systema, Mas
production has the following advantages,
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 ratc al producticn
9 gn n masd pruducjan w h leas cycle une
The
of thc capaciny wilh the help of line balancing.
Proper uilizalian
Nass aroduction does noi rcquire bigh skillead workers, il can be caricd out with the help af acmiskilled or low skilled
workers
a21. What la the purpose of manuhcurnng organzaon in an Industry? Drawa yplca organization atructure of
Lss manulactunng casi pez unu
a manufacturng organbzadon. Also, Explaln the role c PPC department In a manufacturlng compary.
OR
Daadvaatages of Mas Productos System State the purpose of a manufucturing organlzalon in an Industry Glve a typcal organizatlon strucue
Mass production suffers fram few limitationa. They are as follows ofa manutacturlng organzaton

f one machune stops funclioning. then the eniE production Tine would be hall a gi Ogmanion in an Indusm rpica Ognon Srucnur of
2 Aleaion in uhe product desigo would drastically ater the linc layou

. Huge invesneni in prouhuction facilities. OR

Discuss the organization
4In mas produclión, thecycieume S ascertained withthe hclp of the slowes operation. structurn of producuon, planning and control department A i , b a C4
a20. Wrlte any sovan diferent batwaan job shop, batch type and continuoua production system.
OR
Wih the help of an organlzation chart explaln how PPC
OR deparument can camy-out lta functlona
Whal are the diffarencas among Job shop, balch type and conlunuous productlon system7 aMTwacnrine Oanbie ola gf PPC Degp a
Answer
The vanious difierencea amang job shop, batch type and coninuous, OR
Deacribe in briel, planning in manufacture organlzation.
Criterla Job Shop Batch Type Coptiauous Prodactloa
System Answer
1. Meaning The job shop production sysiem Balch production is a type of Continuous production system Parpose ofa Manufacturing Organuatios la an ladustry
that iavolves producuon of one productioa process in which the refon to the fow ofa singleunit Tbe of manufacturing
or few quantiry of producu thaijob in los ar baiches pas through ofproduction between every step purpase organization is s follows
Tb bring manufachuring efcienoy in the productioa plaaning and conrol.
ae designed and produced as per various functional departnen ol the proCess withoui any brrak
customer requiremenis To help the aryanizaioa to automate various manufachurng operauions
intune.
Flow Thereis highly discontinuous flow The Bow ofmaterial id intermilteaMaterials, companenlsandpartu To manage he organization productlon capaclty.
Maienal of maierials. bave continuOLs flow wiboud ary| To manago modes of manufachuring. oypes of Job costung and design of product feanurea.

J. Quanities
backward movemenL To allocale resources for training and development.
t Maaufactures one or few A wbole unibatchofproducts are Productson is carriedout inlarge To increase product quality ai every stage of production line
Prouced number ofs1ngle designed productproduce voumc. To meet the customes eapectations and reduce wastage
strictly accordiog to cuslomer's
Typeal Orgaaattoa Stnucture ef a Manufacturiag Organaatien
specificaion. The following figure shows the typícal struclure ofa manufncuring organizatuoa and tbe role of PPC departmeni in L
. Iypes of
deneral purpose macbines and Special purpose machines are Aulomatie or special parpose
Machines laciliies are used. machines are ued.
employed
3. Example Tailor's abop. vchrcles repaur shop Productuon of Drugs, paiots, Production of cemen, uga
and othersmall workshops. clothes, forging machincs etc petrochemicals, steel ete,
. Wooker PPC Maineanc
Skillb Muli-skilled workers are enployed The workers should be highly is notnecesary1o have skilled
skilled and versatile. s are
abours the machines
designed o suil the requirements
of tbe process.
7. Varnety of There are infinite vanery ol Therc are many variety apartiog
Producis products ofproduts. involves very highvariety of Coolr
product
3. Types of Customzed Variable
Hgar PPC lepartmat lea Typeal Manulasturlog Cemgay
Product Highly sandardized. Role of PPC Department la a Manufacturiog Compauy
9. Audranag planning and control in a factory
can be
comp
provides good cus1omizaiona It craures lexibility, quality aad| iensures high efliciency, ease of According lo Franklin G. Muore, the functions of production ofa planl Juat like the nervos yan
cooirl and large capacity AU Lan orgaaiam nervous ystem. It serves in coordinating coatroltbe ectivities
casy supervisjon. Franklia has also pointed out thal production is accomplished subconsciously he n
s novemens,
epenaive
andcon-repetiüveIt cosily, slow and dilicult
u to
ltrequires high capitalinvestnen 0 ynem reguhles one's breathing, when simple repotithve operations are performod More conacous due
manape aad schedule End i not lexiblg required bouh in theluman syslem and in the plan, when les repealive acivitys involve

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1.18
PRODUCTION PLANNING AND CONTROL (JNTU-KAKINADAJ
vdrtim Paaning and ConroN (PPC) plays an important role in an organization. It is basicallyn service deparment ihat
i d s wbat, wden, whem, how and how much will be pratheed. This departnient is cfosely linked with produotion department.
TbereAre, it is etsenrial o care folly organize the PPC department.
The organization strueture of PPC changes Rom company to company bdsed on thè prbduct'y natureyurodietion volume,
mamafcharing methad be of industry nreds of imdustiy, laynut of plant and the degree of automation.
neTal PPC department is organized as a part of the production division. The heed of production control unit reports
the chief of mamufachuring ie, production manager.
a salloranizstien, PPC work is camied oeut by chiefexecurtive himselfor a person may beappointed to carryout this
P fnctionbeomes soundina medium organization and the number of person engaged in perfoming thia funetion
increses. b caseof hrge ffrms the PPC beromes well-developed department
comprising of hundreds of employees.
The organiatin sucture is comparatively small in continuous
process industries. Also, the
in case af intermittent mdustries, elahorate systems of production are very essential-due toprocedures
ued are quite
simpe. t the high standardizatíon
ofprodacts
a22. Explsn the intemal organtzation of PPC Department.
Amrer
Seming p of PPC intemal structure depends on various important considération. PPC is assigned with diflerent
esed on the nshire
ofindustry, company size and management policies. Diterent companies assign different finctions tofunctions
its PPC
partmeet Onganizations commonly ass1gn the following functions to PPC department,
. Order Preparatien
Order preparstion involres the conversion of sales orders to work
d preparation of auxiliary orders. Subsequently, releasimg these onlers toorders and conversion of work order into shop orderss
the cóncemed authorized
production activities.
2 Material Centrol

Aaterial control or inventory cootrol involves the determinstion

stanrd firished parts and semi finished prodacts is essential wbenever of material requirements. The availability ofmw material
required. This is to ensure that the production
Mars en tiane operation
Tees Coatrol
Tools rontrol is classified into two eategories,
Design and procurement of new tools.
()Desga and economy of jigs and fixtures.
()Controd storage and maintenanee oftools añer procuremem.
Scbeduliag
procs of aranginga production line
Schedoling is a for manufacturing 1he products on time electively withot
se of time and optin uilizton of resourtes. muc
Dispatebine
Dispetching is the routine of setting prodoctive activiies in motion,
through release of orders and
accendance with previowsly planmed timea and sequences as represented in route sheets and instructions e n d :
loading schedules
E1pedinge
Expediting is a process of reviewing the job progress ol an opeatg system and ensuring that it has been pasted thrmd
a o s s s of prodartion without affecting the performance of the proces. The devietjons and delays occur evenh
job peeds to be moed forwerd by the sysiem. , the
Aan from hese fdsans some oganizasions also assign t e funciions such as cos1
estimation, work me suem
deand forecasting, sab-contracting and capecity planning. nent,
Depeadig on the size of he eompany, tbere may be sorme importe cells in PPC depuriment Virious linction .
t PPC for mneging these cels These cells include material control cell, tools control cell, process control cell.sch ed
progressemg cefl dispasching crl, ubcorstract cefl, cost-estimation cell, work measurement cel ete. cell,
Fach cell s menaged by a senior engineer and rwo ausistants and clerks may asist him in plarnning.