PRODUCTION, PLANNING & CONTROL
Production consist of a series of operation to produce useful for customer and need the customer demand so, production is an activity which has a specific objective
Production planning startes with the analysis of given data and on the basis of information studied a plan for the use of resources like m/c material etc is made .after the plan is different operation are performed in a sequence given in the plan
Production control comes into action. If there is any deviation between the actual sequence and the plan being made.the corrective action is then taken to achieve the desired target so PPC May be defined as the direction and cordination of the companies resources to achieve to pre-fix resource
# Objective is PPC :-
The main objective of PPC are
- Systematic planning of production activities to achieve maximum productivity
- To organize facilities like men, m/c ,material etc. To Achieve the states golds of quality, quantity time and cost
- Co-ordination with different departments to achieve unintruppted production flow
- To confirm to the delivery dates given to the customer
- To make suitable adjustment due to changes in demand and order
- To keep the record upto date for better controlling of components
# Stages of PPC :-
1. Process planning :-
It is a method of forecasting every step in a series of operation each step should be taken at right time and the right place. It helps to determine the quantity of material, man power, m/c and money required for producing the required output with the period of time
2. Routing :-
- it is an important function Of PPC and helps in reduce the cost of operation
- It is done to find in advance what will be done for making the product and how much time will be required
- It establishes the path and the sequence of operation needed to make a product
- it tell us to proper m/c require for production
- It gives us the listv of operation require to manufacture a product
- it tells us the best method for carrying out production
3. Route sheets :-
The route sheet or the operation sheet are different to each other. An operation sheet shows everything about the components of production operation where as the route sheet tell the details of various department and the m/c on which work is to be done the operation sheet be done the operation sheet will be remain same if the order is repeated but the route sheet May be unchanged if different m/c are required. The following Points points must kept in mind while drawing route sheets -
- The m/c is operated at full capacity.
- the product passes through those work centre which are operated by experienced employees
- The person solving the problem should have complete knowledge about the operation
# Scheduling :-
It is defined as the alloutment of work to a plant with a specification of time and the sequence in which m/c are to be operated
# Purpose of scheduling :-
- Scheduling is done to achieve the required output with minimum input and minimum time
- To provide raw material so that finished product can be delivered at the dry already fixed
- To achieve maximum effeciency in operation of m/c man power and material handling by maintaining a smooth flow of material along the production line
- To prevent unnecessary delay in production and ensure timely supply of product
- To achieve maximum effeciency and minimum production cost
# M/c loading yard :-
It is a chart prepared to help in production scheduling etc. It shows the amount of work that has been given to a m/c an employee or a group of employee .industries frequently used to m/c loading chart to help in effective and systematic planning of work. Loading and scheduling are done to help in effective planning of work. It gives correct information about the number of m/c available and their operating speed capacity etc. This information is used to calculate the difference between the work load and the actual production capacity and then finally to find the actual date on which production will be completed
# Adjustment of m/c in overloading and underloading condition :-
A m/c is overloaded when the total amount of work given to it is more than it's production capacity overloading can be controlled by
- Proper distribution of work to m/c in idle conditions
- By overtime of employee
- By sub-contracting the work afford
- By purchasing redimate components
# Gantt chart :-
It is a modified bar chart where load is marked against a time scale with one horizontal line alloted to each m/c .develop the following
- Plan for future
- Progress of on present
- Pass achievement
- Relation amoung Various m/c
- Information about expected production delays
- Akarshak attached at the top moves horizontally to tell the present production status and expected date of completion
# Work CPM/ PER :-
To deals with the large scale product various method have been develop these method are known as network techniques such as CPM (critical path path) and part evaluation and preview techniques
# Basic techniques :-
1. Event :-
It represents the start or end of thinks it does not consume any time or resources. It is shown by a circle and writing the event number in that circle .it's exercise are starting a modern installation of m/c etc
2. Activity :-
each Project is made up of operation called activities .activities is doing some work. It consume resources like time Money material etc. An activity start and ends with an event and is shown by an arrow
# Types of activities :-
1. Critical activity :-
Activity called critical activity if it consume more than time than the estimate time. Activity is critical when earlier start and time taken by it equal to the latest finish time
2. Non-critical activity :- These are activities which if consume some extra time then the time estimated the Project will not be delayed
3. Dummy activities :-
These do not consume any time and May be critical or non-critical .these are shown by a dotted arrow
4. Duration :-
It is the time taken to complete a task or a job
5. Critical path :-
It tells us the total Project duration. It is shown by a sequence of critical activities .it consumes maximum resources, maximum time and has the longest path
6. Earliest start time :-
It is calculated by moving from 1st to last event. It is the earliest time on which the activity can be started
7. Earliest finish time :-
It is the earliest possible time to finish an activity. It is calculated by earliest start time plus duration of activities
8. It is the last event .event time of the head event and is calculated by moving back word from the lost event to the first event
9. Latest start time :-
It is the latest possible time at which the activity is start. It is calculated as latest finished time - the duration of activity
10. Slack or float :-
Slack is used with respect to an event and float with respect to an activity .it is the margeable time which a non-critical activity can consume without delay
11. Independent float :-
This is used to reduce the effort on a non-critical activity in order to apply the same effort on a critical activity
12. Total float :-
The additional time of a non-critical activity consume without increasing the project duration the total float can be -ve also
13. Network diagram :-
It is the basic feature of network planning. In this all the event and activities are represented in a proper sequence
# Part techniques :-
Part standard for program evaluation and receive techniques. It describe basic network techniques like planning controlling and monitoring of the project. It is used where a project cannot be easily defined in terms of time and resources requires. Under part the complition time of project is assume to be unknown so the provable time of project compliment is calculated. For a project 3 types are calculated
1. Optimistic time :-
It is best time that can be expected for complition of project if every thing goes well. It is the shortest possible time which are project will take to complete
2. Persimistic time :-
It is the worst time that can be expected if everything goes wrong. It is the longest of all the three estimated time
3. The most likely time :-
It lies between the optimistic time and the persimitic time. It is the time which an activity is expected to consume normally under working condition
The three times are combined to calculate the expected complition time for an activity
The main assumption import techinique is that the 3 estimates form the end point of a curve. It is also assumed that to and Tp occur equally where as the probability of occurance of Dm is four time that of Tp. Therefore expected time Tc= To+ 4Tm+ Tp/ 6
* Advantages of part :-
- It identifies the point of occurance of fault
- It helps the management to find the time and lost of a project
- it suggest areas for increasing effeciency and reducing cost
- it minimizes delays in project complition
- It co-ordinates different part of a Project for timely complition
* Areas of application :-
Part techniques can be applied in
1. Marketing field for advertisement distribution etc
2. It construction industries
3. In general life for planning of our schedule
4. In manufacturing activities like boiler, generator etc
# Estimation :-
It may be defined as the process of finding the probable lost of a product before start of it manufacture
It design pattern making as well as the cost of general administration etc
* Purpose of estimation :-
The main purpose of estimation are
i) to calculate the selling price of a product for a quotation or for a contract
ii) To ensure that the product to be manufacture
iii) To help the management in make or buy decision making
iv) To find out the most economical product making out
v) To prepare the production budget
vi) To find out the method for cost reduction
vii) Estimation so that the price can be announce at the time of launch
* Cost or costing :-
It is defined as a system which records all the expenditure to find the cost of the manufactured product. It can also be defined as a system of accounts department. Which accurately or correctly records all the lost spend on manufacturing a product in all the department .their is a great importance of costing for effective management to provide useful importation in preparing the account Sheel of the company. It shows various points and it's wastage occur and time in loss so that the product can be manufactured in minimum time at minimum cost
* Material cost :-
1. Direct :-
It is the cost of material which are processed in the factory to provide final stage of the product eg:- A metal rod for making bolt a piece of wood for making wooden material etc
2. Indirect :-
* Expenses :-
- Direct :-
These are the expenses that are directly added to a cost of particular job
- Indirect :-
These are the expenses that are non directly added to the Cost of the product
# Overhead and it's type :-
Certain direct and various other indirect expenses that can not be directly included in the production lost but are necessary for production. It if divided into 5 types
1. Production or manufacturing overhead :-
It include indirect expenses starting from receiving the production order to the time when the product is complitely manufactured. Manufacturing overhead cost includes building expensives such as rent, insurance, repair etc. Water cost fuel and electricity and consumable such as grease lubricants, cotton based and extra expenses like security
2. Administration overheard cost :-
It is the lost on direction control at administration of a company it include salaries of clerk general manager, legal cost, portage and telephone etc
3. Selling overhead :-
It consist of cost that is spent to maintain and increase the volume of sales. It include advertisement salaries and commission of agent cost of tour and consumed service etc
4. Distribution overhead :-
It include all the expensions and Storage of a product. It consists of warehouse charges ,cost of transportation loading of products etc
5. Research and development overhead:-
It include the cost spend on during the research and development period of products. This cost is proportional of products. This cost is proportional to the rise and number of employees in a research department
# Difference between CPM and Pert
- CPM
1. It is planning method
2. CPM is activity oriented
3. It has only 1 estimate
4. It is termistic model with 3 defined activity, it consisdered that the expected time to equal expected time is equal to the time taken
5. It is use of dumy activities does not require
6. It marks critical activity
7.it is useful to solve problem of industrial plant maintainance and construction project etc
8. It uses terms like arrow diagram
9 it is use for repetative jobs like planning construction etc
- Pert
1. It is controlling method
2. Pert is went oriented
3. Pert has 3 time estimates that is optimistic, perimistic and most lightly time
4. Pert is a mobamistic model with uncertainty in the duration of activity and is calculated from different time estimate
5. The use of dumy activity is essential for proper path representation
6. Pert does not differentiatiate between critical and non-critical activities
7. It is useful in different project and for research and development
8. Pert uses terms like network diagram events
9. It is used for non-respective jobs such as planning the assembly of a space platform, space craft etc
Production consist of a series of operation to produce useful for customer and need the customer demand so, production is an activity which has a specific objective
Production planning startes with the analysis of given data and on the basis of information studied a plan for the use of resources like m/c material etc is made .after the plan is different operation are performed in a sequence given in the plan
Production control comes into action. If there is any deviation between the actual sequence and the plan being made.the corrective action is then taken to achieve the desired target so PPC May be defined as the direction and cordination of the companies resources to achieve to pre-fix resource
# Objective is PPC :-
The main objective of PPC are
- Systematic planning of production activities to achieve maximum productivity
- To organize facilities like men, m/c ,material etc. To Achieve the states golds of quality, quantity time and cost
- Co-ordination with different departments to achieve unintruppted production flow
- To confirm to the delivery dates given to the customer
- To make suitable adjustment due to changes in demand and order
- To keep the record upto date for better controlling of components
# Stages of PPC :-
1. Process planning :-
It is a method of forecasting every step in a series of operation each step should be taken at right time and the right place. It helps to determine the quantity of material, man power, m/c and money required for producing the required output with the period of time
2. Routing :-
- it is an important function Of PPC and helps in reduce the cost of operation
- It is done to find in advance what will be done for making the product and how much time will be required
- It establishes the path and the sequence of operation needed to make a product
- it tell us to proper m/c require for production
- It gives us the listv of operation require to manufacture a product
- it tells us the best method for carrying out production
3. Route sheets :-
The route sheet or the operation sheet are different to each other. An operation sheet shows everything about the components of production operation where as the route sheet tell the details of various department and the m/c on which work is to be done the operation sheet be done the operation sheet will be remain same if the order is repeated but the route sheet May be unchanged if different m/c are required. The following Points points must kept in mind while drawing route sheets -
- The m/c is operated at full capacity.
- the product passes through those work centre which are operated by experienced employees
- The person solving the problem should have complete knowledge about the operation
# Scheduling :-
It is defined as the alloutment of work to a plant with a specification of time and the sequence in which m/c are to be operated
# Purpose of scheduling :-
- Scheduling is done to achieve the required output with minimum input and minimum time
- To provide raw material so that finished product can be delivered at the dry already fixed
- To achieve maximum effeciency in operation of m/c man power and material handling by maintaining a smooth flow of material along the production line
- To prevent unnecessary delay in production and ensure timely supply of product
- To achieve maximum effeciency and minimum production cost
# M/c loading yard :-
It is a chart prepared to help in production scheduling etc. It shows the amount of work that has been given to a m/c an employee or a group of employee .industries frequently used to m/c loading chart to help in effective and systematic planning of work. Loading and scheduling are done to help in effective planning of work. It gives correct information about the number of m/c available and their operating speed capacity etc. This information is used to calculate the difference between the work load and the actual production capacity and then finally to find the actual date on which production will be completed
# Adjustment of m/c in overloading and underloading condition :-
A m/c is overloaded when the total amount of work given to it is more than it's production capacity overloading can be controlled by
- Proper distribution of work to m/c in idle conditions
- By overtime of employee
- By sub-contracting the work afford
- By purchasing redimate components
# Gantt chart :-
It is a modified bar chart where load is marked against a time scale with one horizontal line alloted to each m/c .develop the following
- Plan for future
- Progress of on present
- Pass achievement
- Relation amoung Various m/c
- Information about expected production delays
- Akarshak attached at the top moves horizontally to tell the present production status and expected date of completion
# Work CPM/ PER :-
To deals with the large scale product various method have been develop these method are known as network techniques such as CPM (critical path path) and part evaluation and preview techniques
# Basic techniques :-
1. Event :-
It represents the start or end of thinks it does not consume any time or resources. It is shown by a circle and writing the event number in that circle .it's exercise are starting a modern installation of m/c etc
2. Activity :-
each Project is made up of operation called activities .activities is doing some work. It consume resources like time Money material etc. An activity start and ends with an event and is shown by an arrow
# Types of activities :-
1. Critical activity :-
Activity called critical activity if it consume more than time than the estimate time. Activity is critical when earlier start and time taken by it equal to the latest finish time
2. Non-critical activity :- These are activities which if consume some extra time then the time estimated the Project will not be delayed
3. Dummy activities :-
These do not consume any time and May be critical or non-critical .these are shown by a dotted arrow
4. Duration :-
It is the time taken to complete a task or a job
5. Critical path :-
It tells us the total Project duration. It is shown by a sequence of critical activities .it consumes maximum resources, maximum time and has the longest path
6. Earliest start time :-
It is calculated by moving from 1st to last event. It is the earliest time on which the activity can be started
7. Earliest finish time :-
It is the earliest possible time to finish an activity. It is calculated by earliest start time plus duration of activities
8. It is the last event .event time of the head event and is calculated by moving back word from the lost event to the first event
9. Latest start time :-
It is the latest possible time at which the activity is start. It is calculated as latest finished time - the duration of activity
10. Slack or float :-
Slack is used with respect to an event and float with respect to an activity .it is the margeable time which a non-critical activity can consume without delay
11. Independent float :-
This is used to reduce the effort on a non-critical activity in order to apply the same effort on a critical activity
12. Total float :-
The additional time of a non-critical activity consume without increasing the project duration the total float can be -ve also
13. Network diagram :-
It is the basic feature of network planning. In this all the event and activities are represented in a proper sequence
# Part techniques :-
Part standard for program evaluation and receive techniques. It describe basic network techniques like planning controlling and monitoring of the project. It is used where a project cannot be easily defined in terms of time and resources requires. Under part the complition time of project is assume to be unknown so the provable time of project compliment is calculated. For a project 3 types are calculated
1. Optimistic time :-
It is best time that can be expected for complition of project if every thing goes well. It is the shortest possible time which are project will take to complete
2. Persimistic time :-
It is the worst time that can be expected if everything goes wrong. It is the longest of all the three estimated time
3. The most likely time :-
It lies between the optimistic time and the persimitic time. It is the time which an activity is expected to consume normally under working condition
The three times are combined to calculate the expected complition time for an activity
The main assumption import techinique is that the 3 estimates form the end point of a curve. It is also assumed that to and Tp occur equally where as the probability of occurance of Dm is four time that of Tp. Therefore expected time Tc= To+ 4Tm+ Tp/ 6
* Advantages of part :-
- It identifies the point of occurance of fault
- It helps the management to find the time and lost of a project
- it suggest areas for increasing effeciency and reducing cost
- it minimizes delays in project complition
- It co-ordinates different part of a Project for timely complition
* Areas of application :-
Part techniques can be applied in
1. Marketing field for advertisement distribution etc
2. It construction industries
3. In general life for planning of our schedule
4. In manufacturing activities like boiler, generator etc
# Estimation :-
It may be defined as the process of finding the probable lost of a product before start of it manufacture
It design pattern making as well as the cost of general administration etc
* Purpose of estimation :-
The main purpose of estimation are
i) to calculate the selling price of a product for a quotation or for a contract
ii) To ensure that the product to be manufacture
iii) To help the management in make or buy decision making
iv) To find out the most economical product making out
v) To prepare the production budget
vi) To find out the method for cost reduction
vii) Estimation so that the price can be announce at the time of launch
* Cost or costing :-
It is defined as a system which records all the expenditure to find the cost of the manufactured product. It can also be defined as a system of accounts department. Which accurately or correctly records all the lost spend on manufacturing a product in all the department .their is a great importance of costing for effective management to provide useful importation in preparing the account Sheel of the company. It shows various points and it's wastage occur and time in loss so that the product can be manufactured in minimum time at minimum cost
* Material cost :-
1. Direct :-
It is the cost of material which are processed in the factory to provide final stage of the product eg:- A metal rod for making bolt a piece of wood for making wooden material etc
2. Indirect :-
* Expenses :-
- Direct :-
These are the expenses that are directly added to a cost of particular job
- Indirect :-
These are the expenses that are non directly added to the Cost of the product
# Overhead and it's type :-
Certain direct and various other indirect expenses that can not be directly included in the production lost but are necessary for production. It if divided into 5 types
1. Production or manufacturing overhead :-
It include indirect expenses starting from receiving the production order to the time when the product is complitely manufactured. Manufacturing overhead cost includes building expensives such as rent, insurance, repair etc. Water cost fuel and electricity and consumable such as grease lubricants, cotton based and extra expenses like security
2. Administration overheard cost :-
It is the lost on direction control at administration of a company it include salaries of clerk general manager, legal cost, portage and telephone etc
3. Selling overhead :-
It consist of cost that is spent to maintain and increase the volume of sales. It include advertisement salaries and commission of agent cost of tour and consumed service etc
4. Distribution overhead :-
It include all the expensions and Storage of a product. It consists of warehouse charges ,cost of transportation loading of products etc
5. Research and development overhead:-
It include the cost spend on during the research and development period of products. This cost is proportional of products. This cost is proportional to the rise and number of employees in a research department
# Difference between CPM and Pert
- CPM
1. It is planning method
2. CPM is activity oriented
3. It has only 1 estimate
4. It is termistic model with 3 defined activity, it consisdered that the expected time to equal expected time is equal to the time taken
5. It is use of dumy activities does not require
6. It marks critical activity
7.it is useful to solve problem of industrial plant maintainance and construction project etc
8. It uses terms like arrow diagram
9 it is use for repetative jobs like planning construction etc
- Pert
1. It is controlling method
2. Pert is went oriented
3. Pert has 3 time estimates that is optimistic, perimistic and most lightly time
4. Pert is a mobamistic model with uncertainty in the duration of activity and is calculated from different time estimate
5. The use of dumy activity is essential for proper path representation
6. Pert does not differentiatiate between critical and non-critical activities
7. It is useful in different project and for research and development
8. Pert uses terms like network diagram events
9. It is used for non-respective jobs such as planning the assembly of a space platform, space craft etc
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