J.B.

Institute of Engineering & Technology

(Autonomous)
Department of Mechanical Engineering
SYLLABUS
Subject Name :Production Planning & Control Subject code. 58015
Class :IV B.Tech - 2 sem.
Sl.No Unit # Details of the unit
1. I Introduction: Definition –Objectives of Production, Planning and Control.
Functions of Production Planning ,and Control- Elements of Production
control – types of Production –Organization of Production Planning and
control –internal organizations departments
2. II Forecasting- Importance of Forecasting – types of forecasting, their uses-
general principles of forecasting techniques – qualitative methods and
quantitative methods.
3. III Inventory Management- Functions in inventory – Relevant inventory cost
ABC analysis – VED analysis – EOQ models – Inventory control systems- P
system and Q system.
4. IV Introduction to MRP and ERP , LOB ( Line of balancing), JIT Inventory,
Japanese concepts
5. V Routing –Definition – routing procedure – Route sheets – Bill of materials.
Factors affecting routing procedure . Schedule – Definition – difference
with loading
6. VI Scheduling polices- techniques standard scheduling methods – job shop,
flow shop
7. VII Line balancing , aggregate planning – methods for aggregate planning
Chase planning , expediting , control aspects
8. VIII Dispatching – Activities of dispatcher – Dispatching procedure – follow up –
definition – reasons for existence of functions – types of follow up.
Application of computer in production planning and control

TEXT BOOKS:
1. Production Planning and Control – M.Mahajan- DhanapatiRai& company
2.Production Planning and Control- Jain& Jain- Khanna Publications
REFERENCES:
1.Production Planning and control- Text & Cases/ SK Mukhopadhyaya/PHI
2.Production and operations Management – R.PannerSelvam- PHI
3.Operations Management by Chase /PHI
4.Management Sciences – A.R.Aryasree 4e –TMH
5.Operations Management –Heizer - Pearson

J.B.Institute of Engineering& Technology

(Autonomous)
Department of _Mechanical Engineering
SUBJECT PLAN :
Subject Name : Production Planning and Control Subject Code : 58015
nd
Class :IVB.Tech 2 sem Faculty NameY.Vijaya Kumar
Unit Number # Topics Total No of Hours
I Introduction: Definition –Objectives of Production,
Planning and Control. Functions of Production Planning
,and Control- Elements of Production control – types of
Production –Organization of Production Planning and
6
control –internal organizations departments
II Forecasting- Importance of Forecasting – types of
forecasting, their uses- general principles of forecasting
techniques – qualitative methods and quantitative
6
methods
III Inventory Management- Functions in inventory –
Relevant inventory cost ABC analysis – VED analysis –
EOQ models – Inventory control systems- P system and Q
10
system.

IV Introduction to MRP and ERP , LOB ( Line of balancing),

JIT Inventory, Japanese concepts
6

V Routing –Definition – routing procedure – Route sheets –

Bill of materials. Factors affecting routing procedure .
Schedule – Definition – difference with loading
6
VI Scheduling polices- techniques standard scheduling
methods – job shop, flow shop
5
VII Line balancing , aggregate planning – methods for
aggregate planning Chase planning , expediting , control
9
aspects

VIII Dispatching – Activities of dispatcher – Dispatching

procedure – follow up –definition – reasons for existence
of functions – types of follow up. Application of computer
6
in production planning and control

Total Hours
54

J.B.Institute of Engineering& Technology

(Autonomous)
Department of Mechanical Engineering

LESSON PLAN :
Subject Name : Production planning and Control Subject Code : 58015
Class : IVB.Tech 2ndsem Faculty Name: Y.Vijaya Kumar
Unit I
S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Introduction- Importance of 1 TB1,RB1,RB2
PPC in; manufacturing and
service oriented Industries
2. Objectives of Production 2 TB1,RB1,RB2
Planning and control.
Functions of Production
Planning and control
3. Elements of Production 3 TB1,RB1,RB2
Planning and Control. Types
of Production , Batch
production, mass production
etc. and differences
4 Importance of Production 4 TB1,RB2
Planning Department and its
organizational chart and its
place in the total
organizational set up
5. Merits and demerits of 5 TB1,RB2
various types of
organizational setups
6. Revision of the total unit 6 TB1,RB2

Unit II

S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Introduction to Forecasting 7 TB1,RB1
2. Importance of forecasting 8 TB1,RB1
and its role in the Industry
3. Types of Forecasting, their 9 TB1,RB1
uses – general principles of
forecasting techniques
4 Qualitative methods 10 TB1,RB1
5. Quantitative methods 11 TB1,RB1
6. Problems 12 TB1,RB2
UNIT III

S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Inventory Management – its 13 TB1,RB1
importance and need
2. Functions in inventory 14 TB1,RB1
3. Eoq models 1 and 2 15 TB1,RB2
4 EOQ models 3 and 4 16 TB1,RB2
5. Worked out problems 17 TB1,RB2
6. Selective inventory controls 18 TB1,RB2
ABC analysis worked out
problems
7. VED analysis and other 19 TB1,RB2
methods of analysis
8 Price break ups and 20 TB1,RB1,RB2
problems
9 Inventory control systems P 21 TB1,RB1,RB2
system and Q system
10. Revision and worked out 22 TB1,RB1,RB2
problems for practice

UNIT IV
S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Introduction to MRP 23 TB1,RB1,SB1
2. Explanation of ERP 24 TB1,RB2,RB3
3. JIT inventory its explanation 25 TB1,RB2,RB3
and need
4 Line of Balance technique 26 TB1,RB2,RB3
5. Worked out problems 27 TB1,RB2,RB3
6. Worked out problems 28 TB1,RB2,RB3
UNIT V
S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Routing and its importance 29 TB1,RB1,SB1
and definition.
2. Routing procedure and 30 TB1,RB2
Route sheets
3. Bill of Materials . How to 31 TB1,RB2
prepare and its uses
4 Factors affecting routing 32 TB1,RB2
procedure
5. Scheduling , definition and 33 TB1,RB2
 its methods
6. Difference with loading and 34 TB1,RB2
revision

UNIT VI

S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Scheduling and its polices 35 TB1,RB1,SB1
2. Scheduling and its 36 TB1,RB1,SB1
techniques
3. Standard scheduling 37 TB1,RB1,SB1
methods
4 Job shop and job flow shop 38 TB1,RB1,SB1
5. Flow shop and revision 39 TB1,RB1,SB1

UNIT VII
S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Aggregate planning – need 46 TB1,RB1,
and importance.
2. Methods of Aggregate 41 TB1,RB1,
planning
3. Worked out problems on 42 TB1,RB1,
Aggregate planning
4 Line balancing need and 43 TB1,RB1,
importance
5. Problems on Line balancing 44 TB1,RB1,
6. Problems on Line Balancing 45 TB1,RB1,
7. Chase planning, expediting 46 TB1,RB1,
8. Control aspects 47 TB1,RB1,
9. Revision of the unit and 48 TB1,RB1,
solving problems of
previous question paper

UNIT VIII
S.No Topic as per syllabus *Lesson # Suggested Question Bank Hand outs
Books ** OQ DQ AQ
(Refer the list)
1. Dispatching and its 49 TB1,RB1,RB2
importance
2. Dispatch procedure and 50 TB1,RB1,RB2
activities in dispatching
3. Reasons for existing 51 TB1,RB1,RB2
functions
 4 Types of follow ups in 52 TB1,RB1,RB2
dispatching the produce
goods/services
5. Computer applications in 53 TB1,RB1,RB2
PPC
6. Revision 54 TB1,RB1,RB2
7. Revision 55 TB1,RB1,RB2

DESCRIPTIVE QUESTIONS.
Unit I
1. Name the various types of production systems. Describe the production system suitable for
job work.
2. What is job order production? State its characteristics. Differentiate between job order
production and batch order systems?
3,Define the term Production Planning and control. State its objectives.
4.Explain the relationship between Production planning and control. Draw a typical
organizational chart of Planning Department in a manufacturing Industry.
5.Explain the activities of Planning in a Manufacturing organization.
6.Define continuous production system. Differentiate between mass production and flow
production.
7.Describe in brief, planning in a manufacturing activity.
8.Define the terms and explain a) Production b) planning and c) control

Unit II
1.Define sales forecasting and explain its importance.
2.State the advantages and limitations of sales forecasting.
3,Descibe various steps involved in sales forecasting.
4.Name various methods of sales forecasting . Describe any two of them with their advantages
and limitations.
5.Describe least square method and forecast demand for the next two years assuming suitable
data.
6.Name the analytical and statistical methods of forecasting. Explain any two them.
7.From the following time series data of sales, project the sales for the next three years.

Year 1975 1976 1977 1978 1979 1980 1981

Sales (in 90 100 102 94 104 98 95
lac of
rupees)

8. use the data in the problem 7, and find out the sales for the next 4 years using least square
method.

Unit III
1.Define Inventory. What are the various types of inventory?
2. Explain the following a) order quantity b) lead time c) safety stock d) Re order point.
3.Define the terms setup cost, holding cost, and shortage or penalty cost. Explain the
constituents of the above mentioned costs .
4. What is EOQ. Derive an equation for the EOQ for any one inventory model.
5.Explain the concept of Q – system, the P system and the two bin system for management of
inventories by giving appropriate examples.
6. What are the various selective Inventory Management systems. Explain them briefly.
7. Describe the ABC analysis and VED analysis. How they are differ from each other?
8. Find the optimal order quantity for a product for which the price break up is as follows.

Unit cost Quantity

Rs.100 0<Q1<500
Rs.92.5 55<Q2<400
Rs.87.5 4000<Q3
9.You are given the following information in regard to an item
Annual usage = 20,000 units
Carrying cost= 20% of the average inventory
Lead time = 10 working days
ordering cost = Rs.160 per order
Unit cost = Rs.2
Total working days = 250 per annum
It is observed that ( from the past data) the demand during lead time has been upto a
maximum level of 150 units per day. Keeping this level in mind, what safety stock would you
recommend? Also determine
a) Re order level when the safety stock level suggested by you is kept in stock b) average level
of inventory stock held and c) ordering and carrying costs associated with this fixed order
inventory policy?
10.The following information is known about a group of items. Classify the items as A,B,C.

Item number Annual consumption Unit price in rupees

in pieces
501 30,000 10
502 2,80,000 15
503 3,000 10
504 1,10,000 5
505 4,000 5
506 2,20,000 10
507 15,000 5
508 80,000 5
509 60,000 15
510 8,000 10
UNIT IV
1.What is the Material resource planning ? What is its purpose?
2.Explain the working of MRP system. Describe the outputs of MRP Systems and also describe
the benefits and limitations of this system.
3.What is ERP? What are the main features?
4. Describe the main features of ERP and explain the methodology of ERP implementation.
5.Define JIT production. State the prerequisites to achieve JIT production.
6.Describe the elements of JIT manufacturing and its characteristics.
7.Describe the line of balance techniques of project scheduling
8.Describe a LOB chart and arrow diagram for the manufacturing of a particular item. Consider
a review period of 5 weeks.

Sub assembly 1
Purchase raw material 1 week
First manufacturing 3 weeks
Second manufacturing 2 weeks
Sub assembly 1 1 week

Sub assembly 2
Purchase parts 2 weeks
First manufacturing 2weeks
Second manufacturing 1 week
Sub assembly II 1 week
Final assembly 2 weeks
Purchase cartons 1 week
Pack for shipment 1 week

The delivery schedule is as follows

Week Number week Number

1 15 11 30
2 19 12 30
3 12 13 30
4 12 14 25
5 13 15 30
6 15 16 30
7 20 17 20
8 20 18 20
9 20 19 15
10 25 20 10
Consider review period as 7 weeks
i) calculate cumulative deliveries for each week
b) Draw LOB chart

Unit V
1 Define routing. Explain the routing procedure in detail.
2. State the objectives of routing and also describe the route sheet with a suitable example.
3.What is scheduling? What are its objectives?
4.Define scheduling and what are its objectives?
5.Desribe a) Master scheduling and b) production scheduling.
6.Explain bill of materials and draw bill of materials for any product.
7.Explain scheduling and what are the factors affecting scheduling?

Unit VI
1.What is scheduling? Explain the tools and techniques for project scheduling?
2.Describe Project cycle curve. Explain the importance.
3. what is PERT and CPM
4.What are the objectives of CPM and PERT?
5.Explain project crash? Explain the method with a suitable example.

Unit VII
1.what is Aggregate planning and what is its importance in a production unit?
2.Describe the relevant cost components in aggregate planning.
3.What is line balancing? What are its objectives?
4.Define various elements of line balancing and explain each term.
5. Describe briefly the steps involved in balancing of an assemble line by a) Kilbridgewester
method and b) RPW method.
6.Demand for a certain sub assembly in a company is 120 items per day. The factory works for 8
hours of two shifts per day. The following eight work elements are required to produce one sub
assembly.

Work 1 2 3 4 5 6 7 8
element
Time 3 5 3 2 2 4 2 2
required in
minutes
Predecesso - - 1,2 2 3 3,4 5,6 7
r

Draw a) precedence diagram b) Determine the cycle time c)Balance the line e) complete line
efficiency, balance delay and smoothness index.

Unit VIII
1.What is dispatching? State various activities of dispatching in brief.
2.Name and describe the common forms of dispatching.
3.What are the uses of various forms used in dispatching?
4.Expalin the following a)Move ticket b) Material requisition form.
5. Differentiate between centralized dispatch and decentralized dispatch.
6.Explain the applications of computer in Production Planning and control.

Objective questions
Unit I
1.The types of production systems are grouped into ----- types.
2.One of the main objectives of PPC is to provide -------- incase of emergencies
3. Shortage of materials in a production unit occurs a) delivery failures b)poor inventory control
methods c) in accurate estimates of future requirements d) all of the above
4.Preparation of detailed work plan is a part of --------- phase of PPC
5.One of the advantage of Production Planning and control is a) benefits to customer b) increase
the cost of product c) keeps quality under control d) none of the above
6.One of the following is not an activity of planning in manufacturing organization is
a) production planning b) scheduling c) hiring of required persons d) tool and jig design
7. The inputs of production system are ------ and -------..
8.According to ------------ the functions of production planning and control can be classified in
ten categories.
Unit II
1.The Fore casting which covers a period of -------- is generally called as short term Forecasting.
2.One of the following is not a method of Sales Forecasting.
a) Executive opinion method b) Market share method c) Monetary policy method d) Survey of
Expert opinion method.
3.In the method of moving average method , average of odd/even periods will be taken into
consideration for arriving at the moving average.
4.The fundamental concept of exponential smoothing method to fore cast is that new estimate =

5.If the demand for a given product is continuously diminishing , the future demand can be
obtained by using --------- method.
6. --------- and ------ is defined as a way of finding out facts, which must be known before a
market policy is to be determined.
7.Compaetaaition studies are generally included s a part of ----
8.Which will helps in business planning by providing a realistic estimate of market trends and
sales possibilities.

Unit III
1.Direct inventories are classified as raw material , ------- , and --------.
2.Total inventory cost is the sum of Purchase cost ,ordering cost and ------
3. ------ is that order quantity which will minimize the total variable cost of managing the
inventory.
4.If R represents demand per year and C3 represents the set up cost and C1 represents the
inventory carrying cost and CP cost per unit price the Economic order quantity is computed with
the formula ------.
5.In order to design systematic ordering system , the method of deciding when to order taking
fixed order quantity as base is called -------
6. The probability of non stocking out during each order cycle is called a) fixed order quantity
system b) periodical ordering system c) service level factor d) total lead time.
7.Selective inventory Management control technique based on annual consumption value is
called --
8.In VED analysis VED stands for ----- ------ ------ which indicates the importance of a
particular item/spare.
9. The Re order level in Inventory Management system is computed as ROL= ------ + -------
10.. If the supplier offers quantity discount then the decision to purchase the quantity is to be
decided by comparing the -------- and -------..

Unit IV
1.The major inputs for MRP are a) Master Production schedule b) Inventory Status file and c) ---
2.. One of the following is not the benefit of the MRP a) Reduction of work in process b)
Effective utilization of capacity c) increase in lead time d) reduction in past due orders.
3.Primary out puts of MRP are a) and b)
4.Exception report is Primary output / secondary output of MRP.
5.The inventory technique which aims for zero inventory is ----
6.A Kanban system is a system of inventory and production control which uses kanbana as the
principle --------- -------- devices.
7.Which system uses master schedules and output of MRP for determining production schedules
and the movement of material in the production unit? Push system or Pull system
8.An ERP ( Enterprise Resource Planning) is aimed at ------ and ------ the enterprises.
9. The objectives of Line of Balance are a) to study the progress of job b) to compare the actual
programme c) to identify the progress of operations which are not satisfactory d0 all the above
10. The PERT and CPM are the ---------- which are used to plan schedule and control of a
project consisting of many inter related activities.

Unit V
1.The specification of the flow or sequence of operations and the process to be followed in
producing a particular manufacturing lot is called ----. according to Alford and Beatty.
2.The main objective of routing is the selection of --- and ----- way to perform a job.
3. one of the following is not the advantages of routing a) efficient use of available resources b)
reduction in manufacturing cost c) increase in cycle time d) improvement in quality.
4.------- is the assignment of work to the facility with the specification of times and the sequence
in which the work is to be done.
5.The following factor affects the scheduling a) customer demand b) availability of stock of
materials c) availability of man power d)all of the above
6.What is the data required for production scheduling a) bill of materials b) out put demand c)
schedule d) none of the above
7.The ------ curve indicates growth , maturity and decay of a product.
8. one of the objective of lading and scheduling is to keep production cost ------.

Unit VI
1.Basic tools and techniques for project scheduling are a) Bar charts b) Line of Balance c) Net
work techniques d) all of the above.
2.A project scheduling technique which is based on the principle of Management by exceptions
is ---
3.Which shows the number of items finished at each of the critical or important operations, in
LOB technique?
4.Schduling may be defend as the ----- of work to the facility with the specifications of times
and the sequences.
5.Availabilty of manpower is internal factor/ external factor which affects scheduling.
6.The objectives of production schedule is to meet output goals of the Master schedule. Yes/No

Unit 7
1. One of the following is not the costs relevant to Aggregate planning a) pay roll costs b) cost
of production rate changes c) cost of overheads d) cost of hiring and laying off workers
2) --------- is the production planning problem of an organization seeking to meet a varying
pattern of demand over an intermediate span of time say one year..
3.Balancing the production line or an assembly line is called --------
4.Methods used for balancing production lines are ---- and-----
5.The strategy adopted in chase planning is ----
6.------ represents the idle time of a workstation and it equals the difference between the cycle
time and the station time.
7.In line balancing the line efficiency is calculated with the formula -----
8.In Kilbridge – Wester heuristic method of Line Balancing the first step of the procedure is
to construct ------.

Unit VIII
1.----- activity ensures that the plans are properly executed.
2. One of the following activity does not a part of dispatching.
a) issue of move order b)issue of inspection order c) issue of job order d) issue of material
procurement order
3.What are the cards used to report labour time utilized and quantity of work performed.
4.The philosophy involved in running the job which arrived in the waiting line first is called ----
5. MRP software programmes generates time wise and period wise requirements of assemblies,
sub assemblies . ( true/false)
6. one of the following functions are done by the software
a)provides control by exception b) plans order size c) determine the neat requirements of the
finished product d) all of the above
7.The document called inspection ticket is the report that indicates the quantity of parts
------ and -----
8. one of the advantage of decentralized dispatching system is -------
 Model Paper 1

Answer any FIVE Questions

1. (a) Explain the procedure involved in carrying ABC analysis.
(b) What are short comings of ABC classification. [16]
2. Explain the following inputs of MRP system:
(a) Master production schedule
(b) Bill of Material
(c) The inventory records _le. [16]
3. Describe the following forms used in dispatching:
(a) Move order
(b) Production ticket. [16]
4. Why the worksheets are prepared ? Give an example of worksheet. [16]
5. How does scheduling in Job shops di_er from High volume continuous systems?
Explain in detail. [16]
6. (a) Explain characteristics of the following:
i. Intermittent and
ii. Continuous production systems.
(b) Mention the nature of PPC function in those respective production system.
[16]
7. The demand for six consecutive periods for a product is as follows:
105,108,112,116,120,130.
(a) Establish a linear forecaster
(b) Determine the forecasted demand in 11th period
(c) Calculate the coefficient of determination and standard deviation for the line
of the best fit. [16]
8. The following list defines the precedence relationships and element times for a
component:

Element Processing time (min) Immediate predecessors

1 0.5 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
8 0.5 3,5
9 0.3 7,8
10 0.6 6,9
The estimated cycle time is 1 min. What is the theoretical number of workstations
required to minimize the balance the delay? Also find the practical number of work
centers using the Ranked positional method. [16]
 Model Paper 2

1. Classify the production systems. Mention characteristics of each of those systems.

[16]
2. Describe the MRP process, including netting, exposing and time phasing. [16]
3. Discuss in detail the sequential steps involved in dispatching. [16]
4. There are five jobs, each of which is to be processed through three machines A, B
and C in the order ABC. Processing times in hours are:
Job A B C
1347
2859
3815
4526
5438
How should the jobs be loaded in order to minimize the total elapsed time? [16]
5. Describe any one quantitative technique used for Assembly line balancing. [16]
6. Explain the following devices used for loading and scheduling:
(a) Produc-Trol Board and
(b) Sched-U-Graph. [16]
7. (a) Show that in exponential smoothing method, weight age to the past data
declines exponentially.
(b) Compare exponential smoothing forecast for different values of smoothing
constant. [16]
8. The store of oil engine repair shop has 10 items whose details are shown in the
following table. Apply ABC analysis to the store: [16]

Component Code Description Price /unit Unit/year

C01 Packing thread 100 100
C02 Tower bolt 200 300
C03 Hexagonal nut 50 700
C04 Bush 300 400
C05 Coupling 500 1000
C06 Bearing (big) 3000 30
C07 Bearing(small) 1000 100
C08 Fuel pump 7000 500
C09 Fixture 5000 105
C10 Drill bit 60 1000
Model 3

1. (a) What is the distinction between a scheduling rule and a scheduling criterion?
(b) Explain the scheduling rules with their relative advantages and disadvantages.
[8+8]
2. Place Aggregate planning in context with the term planning horizon. What is
the appropriate planning horizon for Aggregate planning? Explain the procedure
involved in Aggregate plan. [16]
3. Compare various types of production systems. [16]
4. Discuss in detail the following functions of routing:
(a) Interpretation of detailed drawings
(b) Methods analysis and
(c) Work standards. [16]
5. Suppose a company produces a type of desk that has the BOM given below. The
desk is made by assembling two drawers, two handles, one drawer frame, and two
legs into a drawer module. Then two drawer modules, desk back and a desk top
are assembled into a desk.
(a) Construct a product structure tree and
(b) Construct a production time chart. [16]
Level No Item description No.Required Lead Time(Weeks)
00 Desk 1
01 Desk top 1 2
01 Desk back 1 1
01 Leg/drawer module 2 1
01 Drawer frame 1 1
02 Desk legs 2 1
02 Drawers 2 2
02 Handles 2 2
6. (a) How do you classify inventories into A class, B class and C class items.
(b) Mention the control procedures are to be exercised on A class, B class and C
class items. [16]

7. The following series of 10 observations of sales of a company are given as follows

390, 390, 320, 370, 340, 330, 340, 390, 310, 350 (All figures in Rs. Lakhs).
Given initial forecast is 350 lakhs. Compute the difference between alpha=0.5 and
alpha=0.1. [16]
8. Differentiate between dispatching and expediting and point out to what extent
these differences should lead to a clear and rigid demarcation of responsibilities
between dispatching and expediting. [16]

Model Paper 4
1. Distinguish between the route card and route sheet, with an example. [16]
2. What is the meaning of Aggregate plan? What are the objectives of aggregate
plans? What are the inputs and the nature of the outputs? [16]
3. Discuss the applications of computers in production control. [16]
4. (a) Distinguish between Line Balancing and Line of Balance.
(b) Explain the various steps of Line of Balance technique. [16]
5. (a) Derive expression for smoothing constant.
(b) What are the effects of smoothing constant on the quality of forecast. [16]
6. The Reliance Company has accepted several jobs that are due in the next few days.
A batch of these jobs is assigned to L & T Company. The pertinent data for these
jobs are given below:
Job 1 2 3 4 5 6
Time to process (days) 5 4 3 1 1 2
Due in (days) 11 10 16 2 1 3
(a) Can L & T Company finish all its jobs on time?
(b) Give the schedule that L & T Company should follow in processing these jobs.
Justify your choice of a schedule.
(c) If the company pays a penalty of $10 per day for a job that is tardy but receives
no reward for jobs finished early, what schedule would you recommend to L
& T Company?
(d) If the company receives a reward of $10 per day that a job is early and a penalty
of 10 per day that a job is tardy, what schedule would you recommend to L
& T Company? [16]
7. (a) Explain characteristics of Job shop production system.
(b) Give internal organization chart for Job shop production system. [16]
8. The following information is about a group of items.. Classify the items as A, B
and C: [16]
Item no 501 502 503 504 505 506 507 8 9 10
Annual use 30000 280000 3000 110000 4000 220000 15000 80000 60000 8000
Price 10 15 10 5 5 10 5 5 15 10

Key for Objective questions

Unit I
1. three
2.alternative strategies
3. d
4.action planning
5.a
6.c
7. men, materials. Machines
8.samuel Elison
Unit II
1. 3,6,12 months
2.c
3.odd
4.old estimate of latest actual demand +α( latest actual demand – old estimates of latest actual
demand)
5.graphical
6.Market research – analysis
7.Market analysis
8. Sales forecast
Unit III
1) work in progress, finished products
2.inventory carrying cost
3.EOQ
4.unde root of C3 R /C1 Cp
5.q system
6.c
7.ABC analysis
8.Vital, essential, desirable
9.ROL= Lead time + safety stock
10.cost of EOQ and cost of quantity with reduced price.
Unit IV
1.Bill of materials
2. c
3.planned order schedule and order release note
4. secondary out put
5.JIT
6.information transmission
7.push system
8. modeling and integration
9. d
10. scheduling techniques.
Unit V
1. routing
2. best and cheapest
3.c
4.shcduing
5.d
6.a
7.product life
8. minimum
Unit VI
1.d
2.Line of balance
3. progress chart
4.assignment
5.internal factor
6.yes

Unit VII
1c
2 aggregate plan
3.line balancing
4.sub contracting, diverting extra parts, more than one machine at slower work station
5. hiring and firing
6 delay time =
7.Total station time/cycle time* number of work stations
8.Draw the precedence diagram
Unit VIII
a. dispatch
2. d
3.labour cards/ wage payment cards
4.first come first serve
5.T
6. d
7.passed / rejected
8.easy to solve