QB PPC

UNIT-1 - INTRODUCTION OF PRODUCTION PLANNING AND CONTROL
PART A
1) Define production planning and control (Nov. 2011)
PPC may be defined as the direction and coordination of the organizations materials and physical facilities
towards the attainment of pre-specified goals in the most efficient way.
2) Define production planning
Production planning is defined as the determination, acquisition and arrangement of all facilities necessary
for future production of products.
3) What is meant by production control?
Production control through control mechanism, tries to take corrective action to match the plant and actual
production .Thus production control reviews the progress of the work and takes corrective steps in order to
ensure that programmed production takes place.
4) What are the Phases of PPC?
PPC involves three phases
1. Pre-planning phase, 2. Planning phase, 3. Control phase
5) List the various functions/activities of PPC? (Nov. 2011)
1. Materials planning 6. Scheduling and loading
2. Facility planning 7. Dispatching
3. Methods planning 8. Expediting (or follow up)
4. Estimating 9. Inspection and testing
5. Process planning (routing) 10. Evaluation
6) Differentiate between routing and scheduling
Routing provides the best and the most economical production sequence, whereas scheduling prepares a
logical time- table showing the starting and finishing time of each production work in accordance with
some predetermined program. In simple words routing considers the „where‟ aspects and scheduling
„when‟ aspects.
7) What is Production system? (April 2011)
A production system is the frame work within which the conversion of inputs into output occurs. At the
one end of the production system are the inputs and at the other end outputs.
8) How can you classify the production system?
1. Job shop production
2. Batch production
3. Mass production
4. Process or continuous production
9) What do you mean by batch production?
In batch production, the products are made in small batches and in large variety. Each batch contains
identical items but every batch is different from others.
10) Differentiate between intermittent and continuous production systems.
The job shop production and batch production are also known as intermittent production systems. The
mass production and process production are termed as continuous production system.
11) What types
of plant layouts are suitable for job shop, batch and continuous production?
Job shop production – Process of functional layout

Batch production - Cellular layout

Continuous production – Line or product layout
12) What is the objective of product analysis?
The main objective of product analysis is to obtain qualitative as well as quantitative evaluation of the
influencing factors which determine primarily the success of a manufactured product.
13) Distinguish the terms durability and dependability.
Durability refers to the length of the active life or endurance of the product under given working
conditions.
Dependability refers to the reliability with which the product serves its intended function.
14) What do you mean by design manufacture and design for assembly?
Design for manufacture (DFM) means the design for ease of manufacture of the components of a product.
Design for assembly (DFA) means the design of the product for ease of assembly.
15) What do you understand by product standardization?
Standardization means setting up standards or measuring sticks by which extent, quality, quantity, value,
performance, or service may be gauged or determined.
16) What are the 3S‘s with respect to product development techniques?
1. Standardization 2. Simplification 3. Specialization
17) What do you mean by specialization?
Specialization is the process whereby particular firms concentrate on the manufacture of a limited number
of products or types of products.
18) What are the advantages of specialization?
1. Better utilization of equipment
2. Higher productivity
3. Greater efficiency
4. Better quality
5. Reduced production cost & hence lower unit price, and
6. Use of standardized methods.
19) What do you understand by break-even analysis? (April 2014)
Break-even analysis, also known as cost-volume-profit analysis, is the
study of inter-relationships among a firm‟s sales, costs and operating
profit at various levels of output.
The break-even point is the point at which revenue is exactly equal to
costs. At this point, no profit is made and no losses are incurred. The
break-even point can be expressed in terms of unit sales or dollar sales.
20) Contrast product simplification with product diversification.
Product simplification is the process of reducing the variety of products manufactured i.e., variety
reduction. Product diversification is completely opposite to simplification. Product diversification
involves adding new products or lines products to achieve a balanced product range.
PART B
1. Explain the objectives and benefits of planning and control:
Effective equipment utilization and resources. Improve production rate and optimum loading to
machines. Control work in process inventory and help to achieve production target.
2. Discuss the functions of production planning and control: (April 2008)
Material, method, machine and equipment, routing, loading and scheduling, estimating,
expediting, dispatching, inspection and evaluation.
3. Briefly explain the types of production system:
Comparative study of the production system which comprises of Job, Batch, Mass and continuous
production based on variety of products, volume of production, machines used, type of layout,
required skill level with its merits and demerits.
4. Briefly explain the Product Design and Development:
Need for design. Characteristics for a good product design like repair ability, maintainability,
reliability, modular design, durability, miniaturization etc. Phases in product development which
includes concept development, product planning, product/ process engineering, pilot production.
5. Describe the Factors influencing product design:
Various factors which influence product design like marketing aspect, functional aspect,
operational aspect, aesthetic aspect, economic aspect, production aspect, etc.
6. Describe Standardization: (April 2008)
Definition, Aim, classification of standardization like, Basic standardization, dimensional,
material, equipment, process, quantity, etc. Benefits and limitation of standardization.
7. Write a note on Simplification: (April 2008)
Objectives and benefits of simplification, Effects with respect to % of products with respect to %
of sales income.
8. Briefly discuss about Specialization: (April 2008)
Process by which concentrate on the manufacture of limited number of products or type of
products.
9. What is Break Even analysis: Describe it.
Aims, assumptions, determination of break even point by algebraic method, graphical method.
Problems in Break even point based on various parameters such as quantity, cost and other
variables.
10. Write a note on Economics of new design:
Careful analysis of the economics of the preferred project to be undertaken by introducing a new
model taking into consideration the profits of organization, to avoid declining in sale of the
existing model.
ME 2036 / Production Planning and Control Department of Mechanical Engineering 2014-2015
11. Explain the characteristics features of (i) Batch Production and (ii) Mass Production
Characteristics Features (i) Batch Production (April 2014)
Batch Production is the manufacture of number of identical products either to meet the specific order or to
satisfy the demand. When the Production of plant and equipment is terminated, the plant and equipment
can be used for producing similar products.
This system also can be classified under three categories.
(i) A batch produced only once: Here customer places order with the firm for the product of his
specification. The size of the order is greater than that of job production order. The firm has to plan for the
resources after taking the order from the customer.
(ii) A Batch produced at irregular intervals as per Customer order or when the need arises: As the
frequency is irregular, the firm can maintain a file of its detailed plans and it can refer to its previous files
and start production.
(iii) A Batch Produced periodically at known Intervals: Here the firm either receives order from the
customer at regular intervals or it may produce the product to satisfy the demand. It can have well
designed file of its plans, material requirement and instructions for the ready reference. It can also
purchase materials required in bulk in advance. As the frequency of regular orders goes on increasing the
Batch Production system becomes Mass Production System. Here also, in case the demand for a particular
product ceases, the plant and machinery can be used for producing other products with slight modification
in layout or in machinery and equipment.
Characteristics of Batch Production
(i). Short production runs and frequent changes of setup also characterize batch production.
(ii) The labour force is expected to possess skill in one specific manufacturing process: turning, milling,
drilling, welding, grinding, hobbling, fitting etc.
(iii) Supervisor to possess knowledge of a specific process.
(iv) Limited span of control: The amount of supervision required in batch production is lower than that of
jobbing production.
(v) Machines are grouped on functional basis similar to the job shop manufacturing.
(vi) Manual materials handling: Materials handling in batch production as compared to jobbing production
is small.
(vii) Manufacturing cycle time affected due to queues: The manufacturing cycle time is smaller than
jobbing production but is much more than mass and flow production.
(viii) Flexibility of production schedules
(ix) Plant and Machinery is flexible
(x) Semi automatic, special purpose automatic machines are generally used to take advantage of the
similarity among the products.
(xi) In process inventory is usually high owing to the type of layout and material handling policies
adopted.
(ii) Characteristics of Mass Production System
In mass production, same type of product is manufactured to meet the continuous demand of the product.
Usually demand of the product is very high and market is going to sustain same demand for sufficiently
long time.
The following are the important characteristics of mass production system:
i. As same product is manufactured for sufficiently long time, machines can be laid down in order of
processing sequence. Product type layout is most appropriate for mass production system.
ii. Standard methods and machines are used during part manufacture.
iii. Most of the equipments are semi automatic or automatic in nature.
iv. Material handling is also automatic (such as conveyors).
v. Semi skilled workers are normally employed as most of the facilities are Automatic. As product
flows along a pre defined line, planning and control of the system is much easier.
vi. Cost of production is low owing to the high rate of production.
vii. In process inventories are low as production scheduling is simple and can be implemented with
ease.
viii. Large volume of products
ix. Shorter cycle time of production
x. Extent of supervision of required is less
xi. Because of high volume, cost per unit is low.
12. Why it is necessary to analyze the product. Explain the various analysis that are carried out?
(April 2014)
Analyze the Product - Various Analysis of a Product
(i) Market Analysis - explanation
(ii) Economical and environmental analysis
(iii) Technical Analysis
(iv) Financial Analysis
(v) Break even analysis & Value analysis
UNIT-2 WORK STUDY

PART A
1) Define work study
Work study is a generic term for those techniques, particularly method study and work measurement,
which are used in the examination of human work in all its contexts and which leads systematically to the
investigation of all factors which after the efficiency and economy of the situation being reviewed, in order
to effect improvement.
2) List the objective of work study.
1. To find the most economical way of doing the work
2. To simplify and standardize the methods, materials, tools and equipment.
3. To determine the time required by a qualified worker to perform the work at a normal pace.
4. To plan the training program for the workers for the new methods.
3) Define method study. (Nov. 2011)
Method study is the systematic recording and critical examination of existing and proposed ways of doing
work, as a means of developing and applying easier and more effective methods and reducing costs.
4) List the objectives of method study. (Dec. 2013)
1. To improve the processes and procedures.
2. To improve the design of plant and equipment
3. To improve the plant layout.
4. To improve the use of men, materials and machines.
5. To achieve efficient material handling.
6. To improve the flow of production and processes.
5) Differentiate between operation and inspection.
An operation always takes the material, component or service a stage further towards completion.
An inspection does not take the material any nearer to become a completed product.
It merely verifies that an operation has been carried out correctly as to quality and / or quantity.
6) Differentiate between ‗Permanent storage‘ and ‗Delay‘.
The difference is that a requisition, chit, or other form of formal authorization is generally required to get
an article out of permanent storage but not out of temporary storage.
7) What is a process chart? Mention its types
A process chart is a graphical representation of the sequence of events and related information that occur
in the work method or procedures. There various types of process charts are
Outline process chart, Flow process chart, Two- handed process chart
8) Differentiate between outline process chart and flow process chart.
An outline process chart is a process chart given an overall picture by recording in sequences only the
main operations and inspections. A flow process chart is a graphical representation of all operations,
transportations, inspections, delays and storages occurring during a process or procedure.
9) Distinguish between flow diagram and string diagram.
The sting diagram must be drawn correctly to scale. The flow diagram can be drawn approximately to
scale. The flow diagram would look cumbersome when there are too many to and fro movement between
points but, such movements will not affect the string diagram.
11. Define time study. (Nov. 2011)
Time study is defined as a work measurement technique for recording the times and rates of working for
the elements of a specified conditions and for analyzing the data so as to obtain the time necessary for
carrying out the job at a defined level of performance.
12. Why the job is divided into elements?
i) To ensure that productive work is separated from unproductive activity.
ii) To ensure better and accurate performance rating.
iii) To identify and distinguish different types of elements.
iv) To facilitate checking of method.
13. What is meant by performance rating?
Performance rating is the process of adjusting the actual pace of working of an operator by comparing it
with the mental picture of pace of an operator working at normal speed.
14. List the various allowances to be considered while calculating the standard time of job.
i) Relaxation allowances iv) Interference allowances
ii) Contingency allowances v) Special allowances
iii) Process allowances
15. Define the terms basic time and standard time.
Basic time may be defined as the time for carrying out an element of work standard rating.
Standard time is the time allowed to an operator to carry out the specified task under specified
conditions and defined level of performances.
16. What is meant by work sampling?
Work sampling is defined as a method of finding the percentage occurrence of a certain activity by
statistical sampling and random observations.
17. What do you mean by synthetic data?
Synthetic data is the data derived from the analysis of the accumulated work measurement data in the
form of tables and formulas where the data is arranged in a form suitable for building up the standard
times and similarly machine processing times by synthesis.
18. What is PMTS?
PMTS stands for Predetermined Motion Time System. A predetermined motion time system consists of
a set of time data which has been developed from many observations of a worker‟s performance.
19. Give the acronym for the following: MTA, WFS and MTM.
MTA - Methods Time Analysis, WFS – Work Force System, MTM – Method Time Measurements
20. Define time study.
Time study is defined as a work measurement technique for recording the times and rates of working
for the elements of a specified conditions and for analyzing the data so as to obtain the time necessary
for carrying out the job at a defined level of performance.
21. Define Cumulative timing.
The cumulative timing allows the stopwatch to start at the entire duration of the study.
Accumulated elemental times are recorded in sequence while the watch is running. At the end of the
study, the time for each element is determined by subtracting the beginning time from the end time.
22. What are THERBLIGS. Give any four with symbols. (April 2014)
THERBLIG‟s are the basic building blocks of virtually all manual work performed at a single
workplace and consisting primarily of hand motions. Frank Gilbreth was the first to catalog (list) the
basic motion elements.
Symbols of any two THERBLIG‟s - G – Grasp , A- Assemble , Select , Find ,I-
Inspect , Search .
23. List the steps involved in Time study. (April 2014)
 SELECT(Job to be timed )
 OBTAIN & RECORD(Details regarding method, operator, job & working condition)
 DEFINE(the elements, break the job into element convenient for timing)
 MEASURE ( time duration for each element and assets the rating
 EXTEND(Observed time into normal time[basic time])
 DETERMINE(Relaxation and Personal Allowances)
 COMPUTE(Standard time for the operation for defined job or operation)
24. What are the advantages of SIMO chart? (April 2011)

Simultaneous motion Cycle Chart – (i) The principles behind the multiple activity chart and the two
handed process chart are combined in SIMO chart, (ii) It is drawn on a time based scale, due to that
which allows the job designer to see the relative time taken by each part of the job.
PART B
1. Describe about Method study:
Objectives and advantages of method study, factors facilitating method study, Method study
procedure which include select record using process charts and diagrams. Examine using 5 W,
1 H, and Develop by generating alternatives, Install and maintain the new system.
2. Write a note on Recording of process:
Outline process chart, operation process chart, flow process chart, two handed chart, multiple
activity chart, man machine chart. Flow diagram and string diagram
3. Describe about Micro motion and Memo motion study: (April 2008)
Using therbligs, principles of motion economy.
4. Write a note about Work measurement techniques: (April 2008)
Direct time study, synthesis method, analytical estimating, PMTS, work sampling or activity
sampling.
5. Describe about Time study:
Objective, procedure, selecting the job, selecting the worker, conduct stopwatch time study.
Find various allowances like relaxation allowance, contingency allowance, process allowance
and special allowance, derive the standard time.
6.Write a note on Synthesis method:
Advantages and application, analytical estimating, procedure.
7. Discuss about Predetermined Motion Time System ( PMTS). (April 2008)
Advantages and disadvantage, Type of PMTS, Method Time Measurement, work factor, Basic
motion time.
8. Explain the steps involved in work study. (April 2014)
9. Briefly discuss the steps in work sampling study. (April 2014)

Uses, procedures, steps in work sampling, principles involved in work sampling.
A technique in which a statistically competent number of instantaneous observations are taken over a
period of time, of a group of machine, processes or workers. Each observation recorded for a particular
activity or delay is a measure of the percentage of time observed by the occurrence.
Steps in Work Sampling:
Procedure for conducting the Work sampling Study
(i) Decide on the objective of the study – Set the objective w.r.t duration of study, no of observation,
and d design the study sheet and elemental breakdown based on the objective.
(ii) Obtain the approval of the supervisor – others should understand the purpose of study and obtain
their cooperation.
(iii) Decide upon work and delay elements –
(iv) Decide upon the duration of the study - based on no of observer, objective, accuracy desired and
frequency of occurrence of the activity.
(v) Determine the desired accuracy of results – stated as standard error of a percentage or desired
accuracy – confidence level to be stated.
(vi) Make a preliminary estimate of the percentage occurrence of the activity or delay to be measured.
(vii) Design the study - determine the no of observations to be made- determine no of observers needed
– determine no of days or shifts needed for the study – make the detailed plan for taking observation –
design the observation form.
(viii) Make the observations according to the plan, analyse and summarise the data.
(ix) Check the accuracy or precision of the data at the end of the study.
(x) Prepare the report and state the conclusions.
10. Explain the Stop watch time study
Stopwatch Time Study makes direct observations by means of a simple stopwatch measuring, generally,
to the precision of 0.01 minute. The observation equipment consists of the stopwatch, the recording
board, the observation sheet and a pencil. The steps involved in such a study are:
1. Subdivide the job into observable and distinct elements.
2. Choose acceptable operator/s for study
3. Make direct observations of the work elements while the operator is actually performing the job and
record the time of each element. Make a statistically adequate number of repeated measurements and
record the time of each element. Make a statistically adequate number of repeated measurements and
record each time.
4. Performance rate each element and record
5. Calculate the normal time.
6. Establish allowances
7. Compute the standard time.
The key step in stopwatch time study is that of subdividing the job into component elements. One
should take care that the elements are distinct or well defined and therefore amenable to repeated
measurements. Also, the elements should be as short as possible without losing accuracy of
measurement; the practical minimum is generally 0.02 or 0.03 minute the time required to read and
record being 0.027 minutes or 45 TMU (Time measurement Unit) The following are uses of this
breakdown into elements:
1. It helps in separate performance rating of each of the job elements, instead of performance rating
the whole job (which may lead to much error in the Time Standard).
2. If a job method changes in terms of only one or two elements, the revised time standard can be
easily established in the future, unnecessary time studies are, therefore, eliminated. Standards for
similar or related jobs can also be easily established.
3. It highlights the work element which consumes excessive time, and this can then be subjected to a
critical examination to eliminate/ substitute the element.
4. Element/s with large variation in time can be examined for necessary changes in the job design or
method.
5. It highlights the inconsistency in working conditions.
6. Such division into elements provides a detailed method description which can be used for
training new workers.
UNIT – 3 PRODUCT PLANNING AND PROCESS PLANNING

PART A
1. What is product planning?
i) The evaluation of the range, mix, specification and pricing of existing and new products in relation to
present and future market requirements and competition.
ii) Planning of product range, mix, specification and pricing to satisfy company
object iii) Specifying the research, design and development support required.
2. What is the purpose of feasibility study in relation to product planning?
The purpose of feasibility study is to extend the market analysis with the intent of arriving at a
preferred system configuration that the firm is willing to offer the product or product-mix in response to
an identified need.
3. List the information that can be obtained from the system operation concept.
i) Identification of prime mission of the system
ii) Definition of operating characteristics of the system
iii) Anticipated usage of the system and its elements
iv).Identification of effectiveness factors
4. List the information that can be obtained from the system maintenance concept.
i) Identification of level of maintenance support.
ii) Definition of repair policies
iii) Definition of effectiveness measures
iv). Establishment of supportability requirements in system/ equipment design
v) Establishment of requirements of logistics support
5. List the activities of advanced product planning.
i) Product selection and justification ii) Products specifications and plans
iii) Product acquisition plan iv). Product evaluation plan
6. What is value analysis? (April 2011)
Value analysis is a disciplined approach that ensure the necessary functions at minimum cost without
comprising on quality, reliability, performance and appearance.
7. What is value? List its types
Value, in general, taking the „use value‟ as an objective, is the ratio between the function and the cost.
Value=Types of economic value: 1. Use value, 2. Esteem value, 3. Cost value, 4.Exchange value.
8. How can you increase the value of a product?
The value of a product can be increased:
i) By reducing the costs ii) By improving function
iii) By increasing function by increasing the costs disproportionately low
9. Differentiate between primary and secondary functions with respect to value analysis.
Primary functions are the basic functions which the product is specially designed to perform.
Secondary functions are those which if deleted would not prevent the devices from performing its
primary functions
10. Distinguished between value analysis an value engineering (April 2014).
Value analysis is the application of a set of techniques to an existing product with a view to improve its
value. Thus value analysis is a remedial process.
Value engineering is the application of exactly same set of techniques to a new product at the design
stage itself. Therefore value engineering is a preventive process.
11. Mention any four uses of value analysis.
i) It reduces the cost of product and determines the appropriate cost for the liable performance of
the product.
ii) It helps employees to understand their jobs in a better fashion
iii) It creates new ideas and concepts for R&D department
iv) It creates cost consciousness among the employees in the firm
12. When do you apply value analysis?
Value analysis can be applied in case of the following indications.
i) When the firm is unable to meet delivery schedules
ii) Due to change in technology
iii) When the cost of manufacturing is high
iv) When rate of profit has a falling trend
13. List any four reasons for product‘s unnecessary costs.
i) Failure to utilize specialized knowledge
ii) Poor design of the component
iii) Lack of ideas and relevant information
iv) Unavoidable delivery constraints
14. List the various phases of value analysis.
i) Orientation phase ii) Information phase iii) Functional analysis iv) Creative phase
v) Evaluation phase
15. What is meant by process planning?
Process planning can be defined as “an act of preparing a detailed processing documentation for the
manufacture of a piece part or assembly”.
16. List the various information required for process planning.
1) Assembly and component drawings and bill of materials
2) Machine and equipment details
3) Standard time for each operation and details of set up time for each job
4) Availability of machines, equipment and tools
17. What are the factors affecting process planning?
i) Volume of production
ii) The skill and expertise of man power
iii) Delivery dates for parts or products
iv). Materials specifications
v) Accuracy requirements of parts or products.
18. What is meant by machine balancing?
Machine balancing refers to the procedure of adjusting the times at work centers to conform as much as
possible to the required cycle time.
19. List the commonly used methods to reduce the cycle time to a minimum.
i) Reduce/eliminate idle time in the bottleneck activity
ii) Reduce the independent activity time iii) Reduce the concurrent activity time.
20. What is meant by machine loading?
Machine loading is the process of assigning specific jobs to machines, men or work centers based on
relative priorities and capacity utilization.
21. State the major objective of assembly line balancing. (Nov. 2011)
It is to subdivide the network into several sub networks (stations) without violating the precedence
relationships and allocating operations to each station without exceeding the cycle time. i.e the sum of the
times of operations allocated to each station should not exceed the cycle time.
22. What are the considerations in selection of an equipment or process? (April 2014)
Consideration in selection of an equipment or process -Economic considerations, production rate and unit
cost of production, Durability and dependability, lower process rejection, minimum setups and put away
times, longer productive life of machine or equipment and functional versatility.
PART---B
1. Discuss about Product planning: (April 2008)
Factors to be considered in product planning, which includes marketing factor, product
characteristics, economic analysis and the production factor. Problems in lack of product
planning.
2. Explain the steps in Value Analysis. (April 2014) (April 2008)
Objective, FAST diagram, Various phases involved in value analysis which includes, introduction
phase, documentation phase , recommendation phase, evaluation phase, analysis phase ,
conclusion phase etc. Value Analysis is a systematic approach and it follows a planned and disciplined
procedure to analyze the job.
The Steps in Value Analysis is,
1. Blast
-Selection of the Product
- Collect the relevant Information (Drawings, specifications, Machining & assembly
details, supply details, quantity details, failure details, service records, all cost details etc.)
- Define the Functions – heart of value analysis – Based on Primary and Secondary
functions using FAST
2. Create
- Create the different alternatives
- Critically examine the alternatives
3. Refine
- Develop the best alternative
- Implementation of alternatives
Step 1. Identify the Product
Step 2. Collect relevant information
Step 3. Define different functions
Step 4. Different alternative
Step 5. Critically evaluate the alternatives
Step 6. Develop the best alternatives Step
7. Implement the alternatives.
3. Discuss in detail about Process planning and routing:
Manual process planning and computer aided process planning, important consideration for
process planning, which includes manufacturing specification, determination of raw material and
selection of machine tool.
4. Write a note on Prerequisite information for process planning:
It includes, product data, production volume, quality, available equipment and personnel,
available time, standard time, sequence of operation, material specification.
5. What are the Steps in process planning? Explain in detail (April 2008)
Preparation of drawing, make or buy decision, selection of manufacturing process, machine
capacity, machine selection, selection of material, bill of material, selection of jigs and fixtures,
operation planning and tooling requirements, preparation of documents and preparation of
operation sheet and route sheet.
6. Describe in detail about Quantity determination in batch production problems
Stock control, definition of batch size, minimum cost batch size, Raymond‟s formula, maximum
return, maximum rate of return.
7. What is Machine capacity, balancing?
Line balancing, Variation of time efficiency, balancing to meet demand, estimating capacity,
modifying time efficiency, multi product analysis, graphical representation, analysis by linear
programming.
8. A gear Manufacturer has gear shaper and gear hobbers. The gear can be processed on
gear shaper as well as gear hobber. The following information is given. Which of the two
machines will you choose to do the job if the order quantity if (i) 1000 numbers and order is
unlikely to repeat (ii) 1000 numbers and the order is likely to repeat for 3 years? (April
2014)
Gear Shaper Gear Hobber
Machine time per piece 12 4
(min)
Machine cost per hour (Rs.) 45 120
Set up time (min) 60 90
Tooling up cost (Rs.) 400 2000
9. Explain the steps involved in: i) Product planning ii) Process planning (April 2008)
I. (i) Product Selection (ii) Marketing and marketing Analysis (iii) Performance feasibility
studies, (iv) Advance Planning (v) Specification of requirements
II. Process planning establishes an efficient sequence of operations, select proper equipment and
tooling and specifies their operations in such a manner that the product will meet at requirements
stipulated in the specification.
Process planning must begin during the product design stage where the selection of material and
initial form manufacturing process is decided.
10. Define routing. What are its economic advantages? How route cards are prepared and
what are their uses? (Dec. 2011)
Routing can be defined as the process of deciding the path (route) of work and the sequence of
operations. Routing fixes in advance, the quantity and quality of product, The men, machine and
materials to be used, The type , number and sequence of operations and place of production. The
main objective of routing is to determine the best and cheapest sequence of operations and to
ensure that this sequence is followed in the factory. A route sheet or card lists the manufacturing
operations in proper sequence and associated machine tools for each parts. A route card travels
with the parts which move in batches between the processes from one point in the plant to
another. Route card gives the management information about the work load at each workstation.
It maintains record of sequence of operations which successfully produced a component.
UNIT – 4 PRODUCTION SCHEDULING

PART- A
1. What do you mean by loading?
Loading may be defined as the assignment of work to a facility without specifying when the work is done
and in what sequence.
2. What is scheduling? What are its objectives?
Scheduling refers to the setting of operation start dates so that jobs will be completely by their due date.
The objectives of production scheduling are:
i) To meet due date ii) To minimize lead time iii) To minimize setup time or cost
iv) To minimize work-in process inventory v) To maximize machine or labor utilization
3. What is master scheduling?
The master schedule, also known as master production schedule (MPS), formalize the production plan and
translates it into specific end-item requirements over a short to immediate planning horizon.
4. What is MPS?
The master schedule, also known as master production schedule (MPS), formalize the production plan and
translates it into specific end-item requirements over a short to immediate planning horizon.
5. What are Gantt charts?
Gantt charts are usual aids used to depict the sequencing, load on facilities, or progress associated with
work effort over a well-defined time period.
6. What is priority sequencing?
Priority sequencing is a systematic procedure for assigning priorities to waiting jobs thereby determining
the sequence in which the jobs will be performed.
7. What are the dispatching rules?
Dispatching rules, also known as priority rules or sequencing rules or scheduling rules, are the rules used
in obtaining a job sequence.
8. What is meant by product sequencing?
Priority sequencing is a systematic procedure for assigning priorities to waiting jobs thereby determining
the sequence in which the jobs will be performed.
9. What is meant by EBQ scheduling?
EBQ scheduling is nothing is nothing but the economic batch quantity scheduling that can be performed
by using aggregate run-out method.
10. What do you mean by line-of-balance? What are its uses?
Line-of-balance is a charting technique that uses lead times and assembling sequencing to compare
planned component completion with actual component completions.
11. List the various charts that are used in line-of-balance analysis.
1. Operation programme chart/ or assembly chart, 2. Objective chart 3. Progress chart
4. Line of balance chart
12. What is the use of objective chart?
The objective chart shows the contrast between expected completion schedules of production and the
actual performance.
13. When do you use progress chart?
The progress chart is a bar type chart which shows the actual number of items produced at each operation
stage against the quantities that should have been produced as indicated by line of balance.
14. What is MRP?
Materials requirements planning (MRP) is a computational technique that converts the master schedule for
final products into a detailed schedule for the raw materials and parts used in the final products.
15. List the various inputs required for MRP (April 2011)
1. Master production schedule 2. Bill of materials file 3. Inventory record file
16. What is MPS?
Master Production Schedule (MPS) is a detailed plan that shows how many end items will be available for
sale or distribution during specific periods.
17. List some commonly used forms in dispatching.
1. Material requisitions 2. Job cards/ Tickets 3. Labour cards/Tickets 4. Move cards/Tickets
5. Inspection cards/Tickets 6. Tool and gauge tickets
18. What do you mean by expediting?
Expediting, also known as follow-up or progressing, is a control function that keeps track of the
„progresses of work in accordance with planned schedule.
19. List the various recording methods for the progressing purpose.
1. Gantt charts 2. Visual charts 3. Cumulative and weekly charts
20. What do you mean by dispatching?
Dispatching is the routine of setting productive activities in motion through the release of orders and
instructions, in accordance with previously planned times and sequences, embodied in route sheets and
schedule charts.
21. What is meant by Line Efficiency and Balance Delay. (April 2014)
Line Efficiency – It is the ratio of Total station time to the product of Cycle time and no of work station.
Balance Delay – It is the percentage of total idle time on the line to total time spent by the product from
the beginning to end of line.BD = number of work station X Cycle time –
22. What is meant by Gantt Chart and how it is constructed? (April 2014)
Gantt chart is a principal tool used for both loading and scheduling. It consists of a simple rectangular grid,
divided by series of parallel horizontal and vertical lines. Vertical lines divide the chart into units of time.
The scale units can be year months weeks or days or hours according to the duty for which chart is
required. The horizontal lines divide the chart into sections, which can be used to represent either work
status tasks or work centres. The four jobs which are to be processed on three work centres are shown.
PART—B
1. What do you mean by Production control system, loading and scheduling: Describe
them?
Basic scheduling problems, production loading, multi product scheduling in batch production,
product sequencing, minimum processing time.
1. What is Batch production scheduling. Explain it.
Sequence of batches, optimizing the production schedule, maintaining the stock level, specifying
batch sizes, minimum cost per unit, maximum profit for whole schedule, maximum return to the
whole schedule, deriving a realistic solution.
2. What are the Scheduling techniques: Explain.
Forward scheduling, Backward scheduling, stages in scheduling, loading, dispatching, finite and
infinite loading, load chart ( Gantt chart) , priority sequencing.
3. Explain the Sequencing rules:
Single point sequencing rules, dynamic sequencing rules, basic scheduling problems .Scheduling
and controlling production for delivery schedules, line of balance method.
4. Describe the Material Requirement Planning (MRP or MRP-I):
Objective flow chart, general overview, operation of MRP system, definition and terms used in
MRP system, MRP inputs, Issues in MRP, potential benefits from MRP, Implementation in MRP,
Problems in designing and managing the MRP system, Evaluation of MRP. KANBAN,
Dispatching, Progress routing and expediting, manufacturing lead time, Techniques for aligning
completion time and due dates.
5. An assembly line is to be designed to operate 7.5 hours per day and supply a steady
demand of 300 units per day. The following table shows the tasks and their performance
times. (i) Draw the precedence diagram. (ii) What is the cycle time (iii) Assign tasks to work
stations stating your logical rules (iv) What is the efficiency of your line balance? (April
2014)
Tasks a b c d e f g h i j k l
Precedence
- - - a b c d e f g h,i j
tasks
Performance
70 40 45 10 30 20 60 50 15 25 20 25
time
6. There are seven jobs which are to be processed first on Machine 1 and then on Machine
II. Process time in hours is given below. Find the optimal sequence and total elapsed time.
(April 2014)
Job a b c d e f g
Machine I 6 24 30 12 20 22 18
Machine II 16 20 20 13 24 2 6
7. Briefly explain the various techniques used for loading and scheduling (Dec. 2010)
(i) Loading techniques - Finite and Infinite Loading
(ii) Scheduling – Statistical load Control, Index Method,
8. (i) Briefly explain the five main stages of line of balance technique (Dec. 2010)
Line of Balance is a technique which is used to find out the state of completion of various
process stages of a product which has limited production volume at a given time.LOB is a
suitable technique for finding out the status of completion of differing process stages which
involved in manufacturing of a product. LOB can be applied in the applications of production of
aircraft, missile, heavy machineries / equipments, special equipments etc.
(ii) Explain different techniques employed for aligning completion times and due dates
(Dec. 2010)
(i) EDD (ii) GANTT Chart
9. Explain the significance of scheduling. What are the types of scheduling? (Dec. 2011)
Significance of scheduling: -
It is the allocation of start and finish time to each particular order.
It deals with, when should an operation / job to be started when should it end.
Types of Scheduling
Operation Scheduling, Job Shop Scheduling, Flow Shop Scheduling
10. Explain the following (i) GANTT Chart construction (ii) MRP (Dec. 2011)
(ii) MRP - Material requirements planning (MRP) is a production planning, scheduling, and inventory
control system used to manage manufacturing processes. Materials requirements planning (MRP) is a
computerized inventory planning and control system for determining when (no earlier and no later) and
how many of each of the parts, components, and materials should be ordered or produced. It translates
master schedule requirements fr end items into time-phased requirements for subassemblies, components
and raw materials. Dependent demand drives MRP. MRP is a software system
UNIT-5 ---INVENTRY CONTROL AND RECENT TRENDS IN PPC

PART --A
1) Define term inventory and inventory control.
An inventory is a stock of an item or idle resource held for future use. Inventory control may be defined as
the Scientific method of determining what to order , when to order and how much to order and how much
to stock so that the costs associated with buying and storing are optimal without interrupting production
and sales.
2) Mention at least four reasons for keeping an inventory.
1. To maintain independence of operations. 2. To meet variation in product demand.
3. To allow flexibility in production scheduling.
4. To provide a safeguard for variation in raw material delivery time.
3) What are inventory costs?
The major costs associated with procuring and holding inventories are:
1. Ordering costs, 2. Carrying (or holding) costs, 3. Shortage (or stock out) costs 4. Purchase costs.
4) Define the following terms: (a) Lead time (b) Re-order point
(a)Lead time: The time gap between placing of an order and its actual arrival in the inventory is known as
a lead time.
(b) Re-order point: The level of inventory at which an order is placed is known as Re-order point or re-
orders level.
5) Define the terms buffer stock, and re-order quantity.
Safety or buffer stock: This represents the minimum stock which must be maintained at all times. If stock
is less than the buffer stock, then the work will stop due to shortage of materials.
Re-order quantity: The quantity of items to be ordered at re-orders level is known as re-order quantity.
6) What is EOQ?
The technique of economic ordering quantity (EOQ) strikes a balance between the ordering cost and the
carrying cost. EOQ is the size of order which minimizes the total cost of carrying inventory and ordering.
7) What do you understand by fixed-time period model/
The fixed time period models are also referred to us the periodic system, periodic review system, fixed
order interval system and P model. In a fixed time period system, periodic review of inventories is made
and order is invariably placed in that period.
8) What is JIT? List its Benefits (April 2011)
Just-In-Time is a management that strives to eliminate sources of manufacturing waste by producing the
right part in the right place at the right time.
 Reduction in inventories  Reduced space requirements
 Improved quality  Shorter lead times
 Lower production costs  Increased machine utilization

 Increased productivity  Greater flexibility
9) What are the objectives of JIT? (April 2011)
The JIT is applied to achieve the following goals:
1. Zero defects 4. Zero handling 7. Lot size of one.
2. Zero setup time 5. Zero breakdowns
3. Zero inventories 6. Zero lead time and
10) List the seven wastes that becomes the target of elimination in a JIT process
1. Waste of overproduction 2. Waste of waiting 3. Waste of transportation
4. Waste of processing itself 5. Waste of stocks 6. Waste of motion
7. Waste of making defective products
11).What do you mean by kanban production control system?
Kanban means sign or instruction card in Japanese. A kanban is a card that is attached to a storage and
transport container. It identifies the part number and container capacity, along with other information.
12). Differentiate between Pull system and Push system
A kanban system, is a Pull system, in which the Kanban is used to Pull parts to the next production state
when they are needed i.e., in Pull system product is made to order.
A MRP system is a Push system in which a detail production scheduled for each part is used to Push the
parts to the next production stage when scheduled i.e., in a Push system the product is made to stock.
13).What is MRP II?

MRP II is defined as a computer base system for planning scheduling and controlling the materials,
resources and supporting activities needed to meet the Master Production Schedule. In fact MRP II
consist of virtually functions in a PPC system plus additional business functions that are related to
production.
14) What are the functions of MRP II?
1. Management planning: Business strategy aggregate production planning, maser production
scheduling, rough cut capacity planning and Budget planning.
2. Customer services: Sales forecasting, order entry, sales analysis and finished goods inventory
3. Operations planning: Purchase order and work order release
4. Operations execution: Purchasing, product scheduling and control, work in-process, inventory
control shop floor control and labour hour tracking
5. Financial function: Cost accounts receivable, accounts payable, general ledger and payroll.
15. Define the terms inventory and inventory control?
An inventory is a stock of an item or idle resource held for future use. Inventory control may be defined
as the scientific method of determining what to order, when to order and how much to order and how
much to stock so that costs associated with buying and storing are optimal without interrupting
production and sales.
16. Differentiate between anticipation and fluctuation inventories.
Anticipation inventories: these are stocks maintained to meet the anticipated i.e., expected demand.
Fluctuation inventories: these are safety stocks maintained to meet the unexpected demand and thereby
to avoid the risk of losing sales.
17. Contrast lot size inventories with transportation inventories.
Lot size inventories: Goods are brought in large to get the benefit of discount. The goods so purchased
are stocked unit sale or use. Transportation inventories: When transport of items requires a long time,
then items in transport represent the inventory.
18. Mention at least four reasons for keeping an inventory.
i. To maintain independence of operations ii. To meet variation in product demand
iii. To allow flexibility in production scheduling
iv. To provide a safeguard for variation in raw material delivery time.
19. What are inventory costs? (April 2014).
i) Ordering costs ii) Carrying costs iii) Shortage costs iv) Purchase cost
20. What do you mean by inventory carrying costs?

Inventory carrying costs are the costs associated with holding a given level of inventory on hand. The
holding costs include: i) Costs for storage facilities ii) Handling costs iii) Depreciation, taxes and
insurance iv).Costs on record keeping
21. What is EOQ?
The technique of economic ordering quantity (EOQ) strikes a balance between the ordering cost and the
carrying cost. EOQ is that size of order which minimizes the total costs of carrying inventory and
ordering.
22. What is two bin system? (April 2011)
A two-bin system is a type of fixed-order system in which inventory is carried in two bins. A
replenishment quantity is ordered when the first bin is empty. During the replenishment lead time,
material is used from the second bin. A two-bin system is mostly used in assembly environments. The
advantage of a two-bin system is a minimal chance of a stock-out and the ease to handle. Inventory
control method (used usually for small or low value items) in which when the first bin is used up, an
order is made out for replenishment. The second bin contains enough quantity of the item to last until
the ordered quantity arrives.
23. State the elements of JIT? (April 2014).
Basic elements of JIT - Flexible resources - Cellular layouts -Pull production system - Kanban
production control - Small-lot production - Quick setups - Uniform production levels - Quality at
the source - Total productive maintenance - Supplier networks
24. Mention any four ERP packages that are widely used in India.
1. SAP 2. JD Edwards 3. Manufacturing / Pro 4. BPCS 5. Marshal 6. Oracle Financials
25. List the ―seven wastes‖ that becomes the target of elimination in a JIT process.
i) Waste of over production v) Waste of stocks
ii) Waste of waiting vi) Waste of motion
iii) Waste of transportation vii) Waste of making defective products
iv). Waste of processing itself
PART –B
1. What is Inventory Control? Explain them.
Purpose of holding the stock, functioning of inventory control, effective running of stores,
Technological responsibility for the state of merchandise, stock control system.
2. What are the Effects of demand on inventories?
Effect of a demand impulse on requirement in successive periods, restrictive on output increase,
fluctuation in distribution channels, stock control system.
3. Write about the Ordering procedures:
Two bin system, ordering cycle system, combination of two bin system and the ordering cycle
systems. Reorder quantity, Reorder range, Effect of splitting and order.
4. Discuss about the Reorder procedure:
Reorder point in the two bin system, reorder procedure in the cycle system, effect of uncertainty,
comparison of replenishment policies, optimistic, realistic and pessimistic policies.
5. Discuss about the Determination of Economic order quantity:
Economic lot size, ABC analysis. Introduction to computer integrated production planning system,
Elements of JIT system.
6. Describe about the Fundamentals of MRP-II: (Nov. 2010)
From MRP-I to MRP- II, Evolution of MRP-II, closed loop MRP.
7. Write a note on ERP: (Nov. 2010)
Functioning of ERP, features of ERP, scope and benefits of ERP, applications of ERP, selection of
ERP package.
8. A manufacturer has to supply his customers 3600 units of his product per year. Shortages
are not permitted. Inventory carrying cost amounts Rs.1.2 per unit per annum. The set up
cost per run is Rs.80. Find (i) Economic order quantity (ii) Optimum number of orders per
annum (iii) Average annual inventory cost (iv) Optimum period of supply per optimum order.
(April 2014)
9. Explain briefly the procedure for ABC analysis and list its merits and demerits. (April
2014)
ABC analysis is a basic analytical tool which enables management to concentrate its effort where results
will be greater. It is applied to inventory control. Vital few Trivial Many. A class items constitute 5-10%
of the total items and account for 70-75% of total money spent on inventories. B Class items constitute
10-15% of total items and account for 10-15% of total money spent on materials. C class items are about
70-80 % on total items and account for 5-10% of total money spent on inventories.
Procedure
1. Calculate the total inventory value for each item held in inventory by multiplying the number of units
used in a year by its unit price.
2. Tabulate these items in descending order of their values
placing first the item having the highest total value and soon.
3. Prepare a table showing item no., unit cost, annual units
consumed and annual rupee value of units used.
4. Compute the running total item by item for the items
and also for rupee value of consumption.
5. Compute the cumulative percentage for the item count
and cumulative annual usage value.
6. Classify the items as per the norms for ABC items
7. The cumulative percentage represented graphically as shown above.
Merits:
(i) It helps the manager to exercise selective control and focus his attention only on a few items.
(ii) It is an effective management control tool
(iii) It results in reduced clerical costs, saves time and effort with results in better planning and control
and increased inventory turnover
Demerits:
(i) It is not one time exercise and items are to be reviewed and re-categorized periodically
(ii) It does not permit precise consideration of all relevant problems of inventory management.
10. Alpha industry estimates that it will sell 12,000 units of its products for the forthcoming
year. The ordering cost is Rs. 100 per order and the carrying cost per unit per year is 20
percent of the purchase price per unit. The purchase price per unit is Rs. 50. Find (i)
Economic order quantity (EOQ) (ii) No. of orders per year (iii) Time between successive
orders. (Dec. 2011)
11. The annual demand for an automobile components is 24000 units. The carrying cost is Rs.
0.4/unit/year, the ordering cost is Rs.20.00 per order and the shortage cost is
Rs.10.00/unit/year. Find the optimal values of the following. (i) Economic ordering quantity
(ii) Maximum inventory (iii) Maximum shortage quantity (iv) Cycle time (v) Inventory period
(vi) Shortage period.
12. Compare P and Q systems of inventory replenishments with their merits and demerits
(Nov. 2010)
13. The annual demand of a product is 48000 units. The average leasd time is 4 weks. The
standard deviation of demand during the average lead time is 75 units/ week. The cost of
ordering is Rs.400 per order. The cost of purchase of the product per unit is Rs.10. The cost of
carrying per unit per year is 15% of the purchase price. The maximum delay in lead time is 2
weeks and the probability of this delay is 0.25. Assume a service level of 0.95. (a) If Q system
is followed, find the reorder level. (b) If the P system is followed, find the maximum inventory
level.
Q System
P System

QB PPC

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

QB PPC

Uploaded by

Copyright:

Available Formats

UNIT-1 - INTRODUCTION OF PRODUCTION PLANNING AND CONTROL

UNIT-2 WORK STUDY

24. What are the advantages of SIMO chart? (April 2011)

9. Briefly discuss the steps in work sampling study. (April 2014)

UNIT – 3 PRODUCT PLANNING AND PROCESS PLANNING

UNIT – 4 PRODUCTION SCHEDULING

UNIT-5 ---INVENTRY CONTROL AND RECENT TRENDS IN PPC

 Lower production costs  Increased machine utilization

13).What is MRP II?

20. What do you mean by inventory carrying costs?

You might also like