Production Planning and Control

A Comprehensive Approach

D.R. Kiran

• Publisher: Butterworth-Heinemann
• Year: 2019
• ISBN:
  9780128189375
• Topic: Business
• Subtopic: Operations
• Index: Business

Production Planning and Control draws on practitioner experiences on the shop floor, covering everything a manufacturing or industrial engineer needs to know on the topic. It provides basic knowledge on production functions that are essential for the effective use of PP&C techniques and tools. It is written in an approachable style, thus making it ideal for readers with limited knowledge of production planning. Comprehensive coverage includes quality management, lean management, factory planning, and how they relate to PP&C. End of chapter questions help readers ensure they have grasped the most important concepts.

With its focus on actionable knowledge and broad coverage of essential reference material, this is the ideal PP&C resource to accompany work, research or study.

• Uses practical examples from the industry to clearly illustrate the concepts presented
• Provides a basic overview of statistics to accompany the introduction to forecasting
• Covers the relevance of PP&C to key emerging themes in manufacturing technology, including the Industrial Internet of Things and Industry 4

Chapter 1

Elements of production planning and control

Abstract

The production planning and control department is one of the important departments for a manufacturing company, whatever may be the field of operations. It ensures availability of all materials or components required at the shop floor at the right time, at the right place, and in right quantities to ensure smooth workflow. Whereas all aspects of this function are discussed in this book, this chapter introduces the principles and precepts behind this activity, which will be detailed in subsequent chapters.

Keywords

Role of PP&C; objectives and functions of PP&C; preplanning phase; planning phase; control phase; elements of production; definitions of production planning; long-range versus short-range planning; elements of production control; definitions on production control; essential steps in control activity; O–A–A–E cycle; duties of a production controller; production planning versus production control

Chapter takeaways

After completion of this chapter the reader would be able to

1. 1. Appreciate the role and scope of production planning and control in a successful organization.
2. 2. Appreciate the specific planning and control principles to be applied for long-range and short-range plans.
3. 3. Understand the factor contributing to the complexity of control so as to prepare for any exigencies
4. 4. Relate the P–D–C–A cycle of quality control and the O–A–A–E cycle of production control.
5. 5. Make further study of the references made at the end of the chapter.

1.1 Production planning and control

Production planning and control (PP&C) is the brain and the nervous system of the production program and is responsible for ensuring the availability all materials, part of assembly at the right time, at the right place, and in right quantities in order to enable the progress of operations according to the predetermined schedules at the minimum possible costs. Nevertheless, this function forms part of the production system, and hence we must know more about the production system. PP&C works with procurement, manufacturing, and program management to develop plans to execute customer requirements.

Production planning is dynamic in nature and always remains in a fluid state, as plans may have to be changed according to changes in circumstances. It is mainly concerned with the following important issues:

1. 1. What production facilities are required?
2. 2. How should these production facilities be laid out in the space available for production?
3. 3. How they should they be used to produce the desired products at the desired rate of production?

1.2 Role and scope of production planning and control

• • The type and complexity of the PP&C techniques vary with the type and volume of production.
• • Factories producing large volumes of standardized products need very simple production control techniques.
• • Factories producing a variety of products and product mix also need meticulous control with complex production control techniques.
• • PP&C has to ensure that all the operations are done on all components without exception.
• • PP&C must balance the extent of meticulous control against the costs.

1.3 Objectives of production planning and control

1. 1. Minimize the idle times of men and machines.
2. 2. Minimize inventory turnover.
3. 3. Maximize the percentage of the commitments given to the customers.
4. 4. Maximize the product quality and customer satisfaction.
5. 5. Keep inventory levels low.
6. 6. Provide long runs and low setup times.
7. 7. Minimize bottlenecks along the production flow.
8. 8. Plan early indents to give enough lead time for the purchase of goods at optimal process.

1.4 Functions of production planning and control

While Fig. 1.1 illustrates the several functions of PP&C, we summarize them as follows:

1. 1. Aid forecasting the future for scheduling purposes.
2. 2. Aid cost estimation for new jobs.
3. 3. Receive orders from the marketing department.
4. 4. Translate the schedules into manpower requirements.
5. 5. Decide on make or buy decisions.
6. 6. Determine the material requirements.
7. 7. Maintain the raw material requirement.
8. 8. Determine the machinery requirements and their special attachments, if any.
9. 9. Determine the operations to be performed and the sequence of operations.
10. 10. Prepare operation process charts.
11. 11. E...