Course Plan PPC Revised

2013-14
COURSE PLAN
Regulation: R11
FACULTY DETAILS:
Name of the Faculty:: Y.Vijaya Kumar
Designation: Professor
Department:: Mechanical Engineering
COURSE DETAILS
Name Of The Programme:: B.Tech Batch:: 2010-14
Designation::
Year IV Semester 2nd
Department:: Mechanical Engineering
Title of The Subject Production planning and Subject Code
Control
No of Students 142
2013-14
COURSE PLAN
Regulation: R11
FACULTY DETAILS:
Name of the Faculty::Y.Vijaya Kumar
Designation:Professor
Department:: M.E.
1. TARGET
a) Percentage Pass 100
b) Percentage I class 75 to 80
2. COURSE PLAN
(Please write how you intend to cover the contents: i.e., coverage of Units by lectures, guest lectures, design exercises, solving
numerical problems, demonstration of models, model preparation, or by assignments, etc.)
It is proposed to cover the subject by class room lectures, organising seminars, presentation of slides using OHP and LCD
3. METHOD OF EVALUATION
3.1. X Continuous Assessment Examinations (CAE 1, CAE 2)
3.2. X Assignments / Seminars
3.3. X Mini Projects
3.4. X Quiz
3.5. X Term End Examination
3.6. Others
4. List out any new topic(s) or any innovation you would like to introduce in teaching the subject in this Semester.
Proposed to take the students to an Industry to observe as to how the concepts of PPC
are implemented and their shortcomings and the strategies adopted by the Management to
overcome them.
Y.Vijaya Kumar
Signature of HOD Signature of Faculty
Date: Date:01.03.2014
2013-14
GUIDELINES TO STUDY THE SUBJECT

Regulation: R11
FACULTY DETAILS:
Designation :Professor
Department::Mechanical Engineering
Guidelines for Preparing the Course:
Course Description:
In the modern competitive Industrial environment application of Production Planning control
techniques are vital to avoid the conventional concept of trial and error methods in manufacturing a
quality product at competitive price. The types of production and the scientific methods of forecasting
both qualitative and quantitative are to be analysed for the survival of the Industry. Another
important aspect of Production Management is to assess the inventory requirements in order to
avoid blockage of funds in the form of material stocks and to avoid stoppage of production due to
non availability of required materials. To achieve this target the latest technologies like MRP (Material
Resource Planning),EPR,JIT are required to be analysed and implemented. In the process of product
completion it is necessary to develop schedules for men and machinery to avoid any idle time. The
other techniques like Line of Balancing and Line Balancing, to constantly review the progress of work
and identification of excess load on a particular machine and this needs to be regulated to have equal
load. When once the product is completed the method of despatching the finished products to the
dealer or customer needs to be regulated. All these topics are need to be studied for success full
running of Industry.
Course Objectives:
1. Study of objectives of Production planning and control and their functions in a given
organisation. Study of different types of productions and their advantages over other.
2. Study of scientific methods of forecasting of the demand of a product. Quantitative and
qualitative methods.
3. Explanation of the need of Inventory Management in a production oriented industry.
Evaluation of inventory holding cost and their implications ie holding excess or short .
4. Selective inventory Management techniques and their applications. Study of various
methods of ordering systems based on time and quantity and evaluation of each system
5. Study of the latest techniques like MRP and JIT inventory and their importance in the
industry
6. Examine the Technique of Line of Balancing to monitor the progress of scheduled
productions and identification of bottle necks and to take corrective action. Solve the
given problems.
7. Analysis of preparing bill of materials and studies the procedure of routing and
examines the preparation of route sheets.
8. Examine the various methods of scheduling both for men and machinery and
preparation of job schedules and machine schedules.
9. Examine the method of preparation of Line Balancing to identify the lean machine
timings and load them effectively. Study of Aggregate Planning methods and working
out problems
10. Study the procedure of despatch of products . Types of follow up action. Computer
applications in the area of PPC
Learning Outcomes:
After completion of this subject the student will be exposed to the different approaches to be made
for successful organising an industry in the present competitive environment. The scientific analysis of
demand forecast will be helpful in assessing the demand of a given product. Scheduling of men,
machinery and facilities will give an idea to organise scientific plant layout of facilities to achieve
optimisation. Another area is inventory Management which is a back bone to run the industry in a
successful way. The need of procuring right material at right time in right quantities at right prices is
very essential to keep the product cost at low and competitive levels. The latest technologies like
MRP, JIT, Line of Balancing and Line Balancing can be implemented in manufacturing a product or
service. By completing this subject the student will be able to understand various intricacies involved
in successful running of an industry and solutions thereof.
2013-14
COURSE OBJECTIVES
Regulation: R11
FACULTY DETAILS:
Name of the Faculty: Y.Vijaya Kumar:
On completion of this Subject / Course the student shall be able to:
S.No. Objectives Outcomes

Study of objectives of Production planning and control and their functions in a
given organisation. Study of different types of productions and their advantages
1. over other. D,F,H,J
Study of scientific methods of forecasting of the demand of a product.

2. Quantitative and qualitative methods ,D,E,F,J
Explanation of the need of Inventory Management in a production oriented

industry. Evaluation of inventory holding cost and their implications ie holding
3. excess or short B,E,H,J
Selective inventory Management techniques and their applications. Study of
various methods of ordering systems based on time and quantity and evaluation
of each system
4. C,E,H.
Study of the latest techniques like MRP and JIT inventory and their importance
in the industry
5. C,E,H
Examine the Technique of Line of Balancing to monitor the progress of

scheduled productions and identification of bottle necks and to take corrective
6. action. Solve the given problems C,E.H
Analysis of preparing bill of materials and studies the procedure of routing and
examines the preparation of route sheets.
7. C,H,I
Examine the various methods of scheduling both for men and machinery and
8. preparation of job schedules and machine schedules D,E
Examine the method of preparation of Line Balancing to identify the lean

machine timings and load them effectively. Study of Aggregate Planning
methods and working out problems
9. D,F,J
. Study the procedure of despatch of products . Types of follow up action.

10. Computer applications in the area of PPC B,H,J
Signature of Faculty
Date:01.03.2014
Note: For each of the OBJECTIVE indicate the appropriate OUTCOMES to be achieved.
Kindly refer Page 16, to know the illustrative verbs that can be used to state the objectives.
4
2013-14
COURSE OUTCOMES
Regulation: R11
FACULTY DETAILS:
Name of the Faculty: Y.Vijaya Kumar:
The expected outcomes of the Course / Subject are:
S.No. General Categories of Outcomes Specific Outcomes of the Course

Design the arrow diagrams in implementation of Line
Balancing, and solving various scheduling techniques
An ability to apply knowledge of mathematics, of machining and manpower.
A. science, and engineering
To estimate the demand forecasting of the products by

An ability to design and conduct experiments, as collecting and analyzing data from various sources
B. well as to analyze and interpret data
Understand the objectives of production planning &

control and various types of production systems. Study
of various types of production organizations both for
An ability to design a system, component, or PPC and for product manufacturing.
C. process to meet desired needs within realistic
Constraints such as economic, environmental,
social, political, ethical, health and safety,
Manufacturability and sustainability
For preparing assessment of demand of the product the
D. An ability to function on multi-disciplinary teams methods of coordinating with other Departments
Evaluate the schedules for machines and manpower,

Line balancing . Workout the requirements of various
An ability to identify, formulate, and solve resources in Aggregate Planning.
E. engineering problems
Understand the high profile concepts like MRP, JIT and

ERP and implementation of these techniques in
An understanding of professional and ethical production oriented Industries.
F. responsibility
Comprehend the demand forecast requirements and

G. An ability to communicate effectively ability to collect data from different sources
Understand the software programmes on ERP and

The broad education necessary to understand the acquiring the process of computer applications in PPC
H. impact of engineering solutions in a global,
economic, environmental, and societal context
To constantly review the products/ services being
produced and look for diversification or expansion to
A recognition of the need for, and an ability to have a life time continuity.
I. engage in life-long learning
Study of practices relating to PPC in other

J. A knowledge of contemporary issues contemporary Industries.
Understand all latest modules in implementing

An ability to use the techniques, skills, and computerisation.
K. modern engineering tools necessary for
engineering practice.
Objectives – Outcome Relationship Matrix (Indicate the relationships by  mark).

Outcomes
Objectives A B C D E F G H I J K
1.    
2.    
3.    
4.   
5.   
6.   
7.   
8.  
9.   
10.   
5
FACULTY DETAILS:
The Schedule for the whole Course / Subject is:: 54 Hours
2013-14
COURSE SCHEDULE
Regulation: R11
Duration (Date) Total No.

S. No. Description
From To of Periods
Introduction: Definition –Objectives of Production,
Planning and Control. Functions of Production
Planning ,and Control- Elements of Production control
1.
– types of Production –Organization of Production
Planning and control –internal organizations
departments 9.12.13 20.12.13 6
Forecasting- Importance of Forecasting – types of

forecasting, their uses- general principles of
2.
forecasting techniques – qualitative methods and
quantitative methods 27..12.13 07.01.14 6
Inventory Management- Functions in inventory –

Relevant inventory cost ABC analysis – VED analysis
3.
– EOQ models – Inventory control systems- P system
and Q system 10.01.14 01.02.14 10
4. 03.2.14 14.02.14
Introduction to MRP and ERP , LOB ( Line of
balancing), JIT Inventory, Japanese concepts 6
Routing –Definition – routing procedure – Route
sheets – Bill of materials. Factors affecting routing
5.
procedure . Schedule – Definition – difference with
loading 15.02.14 to 24.02.14
6
Scheduling polices- techniques standard scheduling
6. methods – job shop, flow shop
25.02.14 01.03.14
5
Line balancing , aggregate planning – methods for
aggregate planning Chase planning , expediting ,
7 control aspects
9
03.03.14 to 21.03.14
8 Dispatching – Activities of dispatcher – Dispatching 25.03.14 04.04.14 6
procedure – follow up –definition – reasons for
existence of functions – types of follow up.
Application of computer in production planning and
control
Total No. of Instructional periods available for the course: Hours / Periods 54
Text Books
1. Production Planning and Control by M.Mahajan-Dhanapatirai Publishers
2.Production Planning and control by Jain and Jain
3.Production and operations management by R.Pannerselvam
SCHEDULE OF INSTRUCTIONS 2013-14
UNIT - I Regulation: R11
FACULTY DETAILS:
Department:: ME
Objectives & References

SI. No. of
Date Topics / Sub - Topics Outcome (Text Book, Journal…)
No. Periods
Nos. Page No___ to ___
Introduction- Importance of PPC in; Production and
manufacturing and service oriented planning and control
09.1 Industries 1 by M.Mahajan page
1 2.13 1 &D,F,H no 1 to 22
Objectives of Production Planning and Production and
control. Functions of Production Planning planning and control
10.1 and control 1 by M.Mahajan page
2 2 1 &D,F,H no 1 to 22
Elements of Production Planning and Production and
Control. Types of Production , Batch planning and control
14.1 production, mass production etc. and 1 by M.Mahajan page
3 2 1 differences &D,F,H no 1 to 22
Importance of Production Planning Production and
Department and its organizational chart planning and control
16.1 and its place in the total organizational 1 by M.Mahajan page
4 2 1 set up &D,F,H no 1 to 22
Merits and demerits of various types of Production and
organizational setups planning and control
17.1 1 by M.Mahajan page
5 2 1 &D,F,H no 1 to 22
Revision of the total unit Production and
1 planning and control
20.1 &D,F,H, by M.Mahajan page
6 2 1 J no 1 to 22
Date 01.03.14
Note: 1. ENSURE THAT ALL TOPICS SPECIFIED IN THE COURSE ARE MENTIONED.
2. ADDITIONAL TOPICS COVERED, IF ANY, MAY ALSO BE SPECIFIED BOLDLY.
3. MENTION THE CORRESPONDING COURSE OBJECTIVE AND OUT COME NUMBERS AGAINST EACH TOPIC .
UNIT - II Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
D
at
e Topics / Sub - Topics Outcome (Text Book, Journal…)
No. Periods
Introduction to Forecasting Production and
2& planning and control
27.12.1 D.E by M.Mahajan page
7 3 1 .F.J no 49 to 70
Importance of forecasting and its role in Production and
the Industry 2& planning and control
30.12.1 D.E by M.Mahajan page
8 3 1 .F.J no 49 to 70
Types of Forecasting, their uses – general Production and
principles of forecasting techniques 2& planning and control
D.E by M.Mahajan page
9 3.01.14 1 .F.J no 49 to 70
Qualitative methods Production and
10 4.01.14 1 .F.J no 49 to 70
Quantitative methods Production and
11 6.01.14 1 .F.J no 49 to 70
Problems Production and
12 7.01.14 1 .F.J no 49 to 70
Date 01.03.2014
MENTION THE CORRESPONDING COURSE OBJECTIVE AND OUT COME NUMBERS AGAINST EACH TOPIC .
UNIT - III Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
O
ut
co
m
Date Topics / Sub - Topics e (Text Book, Journal…)
No. Periods
N
os
. Page No___ to ___
Inventory Management – its importance Production and
and need planning and control
10.01.1 3,4& by M.Mahajan page
13 4 1 B,E,H,J no 283 to 364
Functions in inventory Production and
planning and control
20.01.1 34,& by M.Mahajan page
14 4 1 B,E,H,J no 283 to 364
Eoq models 1 and 2 Production and
15 4 1 B,E,H,J no 283 to 364
EOQ models 3 and 4 Production and
16 4 1 B,E,H,J no 283 to 364
Worked out problems Production and
17 4 1 B,E,H,J no 283 to 364
Selective inventory controls Production and
ABC analysis worked out problems planning and control
18 4 1 B,E,H,J no 283 to 364
VED analysis and other methods of Production and
analysis planning and control
19 4 1 B,E,H,J no 283 to 364
Price break ups and problems Production and
20 4 1 B,E,H,J no 283 to 364
21 31.01.1 1 Inventory control systems P system and 3,& Production and
4 Q system B,E,H,J planning and control
by M.Mahajan page
no 283 to 364
Revision and worked out problems for
practice 3,4&
22 01.2.14 1 B,E,H,J
Date
MENTION THE CORRESPONDING COURSE OBJECTIVE AND OsUT COME NUMBERS AGAINST EACH TOPIC .
UNIT - IV Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
No. Periods
Introduction to MRP Production and
5&C, by M.Mahajan page
23 3.02.14 1 E,H no 173 to 184
Explanation of ERP Production and
24 4.02.14 1 E,H no 173 to 184
JIT inventory its explanation and need Production and
25 7.02.14 1 E,H no 173 to 184
Line of Balance technique Production and
26 10.2.14 1 E,H no 173 to 184
27 11.2.14 1 E,H no 173 to 184
28 14.2.14 1 E,H no 173 to 184
Date 01.03.14
UNIT - V Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
No. Periods
Routing and its importance and Production and
definition. planning and control
6& by M.Mahajan page
29 15.2.14 1 C,E.H no 205 to 238
Routing procedure and Route sheets Production and
30 17.2.14 1 C,E.H no 205 to 238
Bill of Materials . How to prepare and its Production and
uses planning and control
31 18.2.14 1 C,E.H no 205 to 238
Factors affecting routing procedure Production and
32 21.2.14 1 C,E.H no 205 to 238
Scheduling , definition and its methods Production and
33 22.2.14 1 C,E.H no 205 to 238
Difference with loading and revision Production and
34 24.2.14 1 C,E.H no 205 to 238
Date 01.03.14
UNIT - VI Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
No. Periods
Scheduling and its polices Production and
35 25.2.14 H,I no 209 to 238
Scheduling and its techniques Production and
7&C,H, by M.Mahajan page
36 26.2.14 I no 209 to 238
Standard scheduling methods Production and
by M.Mahajan page
37 27.2.14 7&C,H,I no 209 to 238
Job shop and job flow shop Production and
7&C,H, by M.Mahajan page
38 28.2.14 I no 209 to 238
Flow shop and revision Production and
39 1.3.14 H,I no 209 to 238
Date 01.03.2014
UNIT - VII Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
No. Periods
Aggregate planning – need and Production and
importance. planning and control
8,9& by M.Mahajan page
D.E.F no 173to 184,239 to
40 03.03.14 .J 267
Methods of Aggregate planning Production and
D.E.F no 173to 184,239 to
41 06.03.14 .J 267
Worked out problems on Aggregate Production and
planning planning and control
D.E.F no 173to 184,239 to
42 07.03.14 .J 267
Line balancing need and importance Production and
D.E.F no 173to 184,239 to
43 08.03.14 .J 267
Problems on Line balancing Production and
D.E.F no 173to 184,239 to
44 14.03.14 .J 267
Problems on Line Balancing Production and
D.E.F no 173to 184,239 to
45 18.03.14 .J 267
Chase planning, expediting Production and
D.E.F no 173to 184,239 to
46 19.03.14 .J 267
Control aspects 8,9&
D.E.F
47 20.03.14 .J
Revision of the unit and solving problems Production and
48 21.03.14 of previous question paper planning and control
by M.Mahajan page
no 173to 184,239 to
267
Date
UNIT - VIII Regulation: R11
FACULTY DETAILS:
Department:: ME

SI. No. of
D
at
e Topics / Sub - Topics Outcome (Text Book, Journal…)
No. Periods
Nos Page No___ to ___
Dispatching and its importance Production and
25.03.1 10,B&H by M.Mahajan page
49 4 1 ,J. no 230 to 238
Dispatch procedure and activities in Production and
dispatching planning and control
50 4 1 ,J. no 230 to 238
Reasons for existing functions Production and
51 4 1 ,J. no 230 to 238
Types of follow ups in dispatching the Production and
produce goods/services planning and control
10,B&H by M.Mahajan page
52 1.04.14 1 ,J. no 230 to 238
Computer applications in PPC Production and
53 2.04.14 1 ,J. no 230 to 238
Revision Production and
54 3.04.14 1 ,J. no 230 to 238
Revision Production and
55 4.04.14 1 ,J. no 230 to 238
Date 01.03.14
2013-14
COURSE COMPLETION
STATUS
Regulation: R11
FACULTY DETAILS:
Subject:: Professor Subject Code
Department:: ME
Actual Date of Completion & Remarks, if any 11.04.2014 (Expected date) 54 Hours
Nos. of
Units Remarks Remarks Objectives
Achieved
Completed all the topics specified in the syllabus and
Unit 1 cleared the quires raised by the students All

cleared the quires raised by the students. Explained the
working of IC Engine with the help of cut models and
shown video clippings on the working of various
Unit 2 systems. All



Completed all the topics specified in the syllabus and cleared the quires raised by the students
Unit 6 All
cleared the quires raised by the students
Unit 7

Signature of Dean of School Signature of Faculty

Date: Date:
NOTE: AFTER THE COMPLETION OF EACH UNIT MENTION THE NUMBER OF OBJECTIVES ACHIEVED.
2013-14
TUTORIAL SHEETS - I
Regulation: R11
FACULTY DETAILS:
Department:: ME
Date: 24.12 to
27.12
This Tutorial corresponds to Unit Nos.1 to 3 Time:
Q1. . What is job order production? State its characteristics. Differentiate between job order
production and batch order systems?
2,Define the term Production Planning and control. State its objectives.
3.Name various methods of sales forecasting . Describe any two of them with their advantages
and limitations.
4.Describe least square method and forecast demand for the next two years assuming suitable
data.
5.Name the analytical and statistical methods of forecasting. Explain any two them
6. What is EOQ. Derive an equation for the EOQ for any one inventory model.
7.Explain the concept of Q – system, the P system and the two bin system for management of
inventories by giving appropriate examples.
8. What are the various selective Inventory Management systems. Explain them briefly.
Please write the Questions / Problems / Exercises which you would like to give to the students and also mention the objectives
to which these questions / Problems are related.

Date: Date:
2013-14
TUTORIAL SHEETS - II
Regulation: R11
FACULTY DETAILS:
Department:: ME
Date: 28.2 to 3.2.14

This Tutorial corresponds to Unit Nos.4 to 6 Time:
. 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.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. what is PERT and CPM
8.What are the objectives of CPM and PERT?

Date: Date:01.03.2014
FACULTY DETAILS:
Department:: ME
2013-14
TUTORIAL SHEETS - III

Regulation: R11
Date: 4.04.14 to
08.04.14
This Tutorial corresponds to Unit Nos. Time:
1.Describe the relevant cost components in aggregate planning.
2.What is line balancing? What are its objectives?
3.Define various elements of line balancing and explain each term.
4. Describe briefly the steps involved in balancing of an assemble line by a) Kilbridgewester

method and b) RPW method.
5.Name and describe the common forms of dispatching.
6.What are the uses of various forms used in dispatching?
7.Expalin the following a)Move ticket b) Material requisition form.

Date: Date: 01.03.14
2013-14
ILLUSTRATIVE VERBS
FOR STATING
INSTRUCTIONAL OBJECTIVES Regulation: R11
These verbs can also be used while framing questions for Continuous Assessment Examinations as well as for End –
Semester (final) Examinations.
ILLUSTRATIVE VERBS FOR STATING GENERAL OBJECTIVES
Know Understand Analyze Generate

Comprehend Apply Design Evaluate
ILLUSTRATIVE VERBS FOR STATING SPECIFIC OBJECTIVES:

A. Cognitive Domain
1 2 3 4 5 6
Comprehension
Knowledge Application Analysis Synthesis Evaluation
Understanding
of knowledge & of whole w.r.t. its combination of
judgement
comprehension constituents ideas/constituents
Define Convert Change Breakdown Categorize Appraise

Identify Defend Compute Differentiate Combine Compare
Label Describe (a Demonstrate Discriminate Compile Conclude
List procedure) Deduce Distinguish Compose Contrast
Match Distinguish Manipulate Separate Create Criticize
Reproduce Estimate Modify Subdivide Devise Justify
Select Explain why/how Predict Design Interpret
State Extend Prepare Generate Support
Generalize Relate Organize
Give examples Show Plan
Illustrate Solve Rearrange
Infer Reconstruct
Summarize Reorganize
Revise
B. Affective Domain C. Psychomotor Domain (skill development)

Adhere Resolve Bend Dissect Insert Perform Straighten
Assist Select Calibrate Draw Keep Prepare Strengthen
Attend Serve Compress Extend Elongate Remove Time
Change Share Conduct Feed Limit Replace Transfer
Develop Connect File Manipulate Report Type
Help Convert Grow Move preciselyReset Weigh
Influence Decrease Handle Operate Run
Initiate Demonstrate Increase Paint Set
2013-14
LESSON PLAN
Unit-1
Regulation: R11
Name of the Faculty: Y.Vijaya Kumar

Subject Production Planning and Control Subject Code
Unit
INSTRUCTIONAL OBJECTIVES:
Session Teaching
Topics to be covered
No Time Ref Method
Introduction- Importance of PPC in; manufacturing and service Class room

lecture,
1 oriented Industries T1.T2. T3
OHP,
seminars
Objectives of Production Planning and control. Functions of Class room
lecture,
2 Production Planning and control T1.T2. T3
OHP,
seminars
Elements of Production Planning and Control. Types of Class room
Production , Batch production, mass production etc. and lecture,
3 T1.T2. T3
OHP,
differences
seminars
Importance of Production Planning Department and its Class room
organizational chart and its place in the total organizational set lecture,
4 T1.T2. T3
OHP,
up
seminars
Merits and demerits of various types of organizational setups Class room
lecture,
5 T1.T2. T3
OHP,
seminars
Revision of the total unit Class room
6 T1.T2. T3 lecture, OHP
,seminars
On completion of this lesson the student shall be able to(Outcomes)

1.D,F,H,J
2.
3.
4
2013-14
ASSIGNMENT
Unit-I
Regulation: R11
Assignment / Questions
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
Note: Mention for each question the relevant objectives and outcomes.
2013-14
LESSON PLAN
Unit-II
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Introduction to Forecasting Class room

lecture,
7 T1.T2. T3
OHP,
seminars
Importance of forecasting and its role in the Industry Class room
lecture,
8 T1.T2. T3
OHP,
seminars
Types of Forecasting, their uses – general principles of Class room
lecture,
9 forecasting techniques T1.T2. T3
OHP,
seminars
Qualitative methods Class room
lecture,
10 T1.T2. T3
OHP,
seminars
Quantitative methods Class room
lecture,
11 T1.T2. T3
OHP,
seminars
Problems Class room
lecture,
12 T1.T2. T3
OHP,
seminars
On completion of this lesson the student shall be able to

1.D,E,F,J
2.
3.
4
2013-14
ASSIGNMENT
Unit-II
Regulation: R11
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.
2013-14
LESSON PLAN
Unit-III
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Inventory Management – its importance and need Class room

lecture,
13 T1.T2. T3
OHP,
seminars
Functions in inventory Class room
lecture,
14 T1.T2. T3
OHP,
seminars
Eoq models 1 and 2 Class room
lecture,
15 T1.T2. T3
OHP,
seminars
EOQ models 3 and 4 Class room
lecture,
16 T1.T2. T3
OHP,
seminars
Worked out problems Class room
lecture,
17 T1.T2. T3
OHP,
seminars
Selective inventory controls Class room
lecture,
18 T1.T2. T3
ABC analysis worked out problems OHP,
seminars
VED analysis and other methods of analysis Class room
lecture,
19 T1.T2. T3
OHP,
seminars
Price break ups and problems Class room
lecture,
20 T1.T2. T3
OHP,
seminars
Inventory control systems P system and Q system Class room
lecture,
21 T1.T2. T3
OHP,
seminars
Revision and worked out problems for practice Class room
lecture,
22 T1.T2. T3
OHP,
seminars
On completion of this lesson the student shall be able to(Outcomes)
1.B,E,H,J
2.
3.
4
2013-14
ASSIGNMENT
Unit-III
Regulation: R11
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
2013-14
LESSON PLAN
Unit-IV
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Introduction to MRP Class room

lecture,
23 T1.T2. T3
OHP,
seminars
Explanation of ERP Class room
lecture,
24 T1.T2. T3
OHP,
seminars
JIT inventory its explanation and need Class room
lecture,
25 T1.T2. T3
OHP,
seminars
Line of Balance technique Class room
lecture,
26 T1.T2. T3
OHP,
seminars
lecture,
27 T1.T2. T3
OHP,
seminars
lecture,
28 T1.T2. T3
OHP,
seminars
On completion of this lesson the student shall be able to (Outcomes)

1. C,e,H
2.
3.
4
2013-14
ASSIGNMENT
Unit-IV
Regulation: R11
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
2013-14
LESSON PLAN
Unit-V
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Routing and its importance and definition. Class room

lecture,
29 T1.T2
OHP,
seminars
Routing procedure and Route sheets Class room
lecture,
30 T1.T2
OHP,
seminars
Bill of Materials . How to prepare and its uses Class room
lecture,
31 T1.T2
OHP,
seminars
Factors affecting routing procedure Class room
lecture,
32 T1.T2
OHP,
seminars
Scheduling , definition and its methods Class room
lecture,
33 T1.T2
OHP,
seminars
Difference with loading and revision Class room
lecture,
34 T1.T2
OHP,
seminars

1. C,E,H
2.
3.
4
2013-14
ASSIGNMENT
Unit-V
Regulation: R11
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?
2013-14
LESSON PLAN
Unit-VI
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Scheduling and its polices Class room

lecture,
35 T1,T2
OHP,
seminars
Scheduling and its techniques Class room
lecture,
36 T1,T2
OHP,
seminars
Standard scheduling methods Class room
lecture,
37 T1,T2
OHP,
seminars
Job shop and job flow shop Class room
lecture,
38 T1,T2
OHP,
seminars
Flow shop and revision Class room
lecture,
39 T1,T2
OHP,
seminars

1. C,E,H,I
2.
3.
4
2013-14
ASSIGNMENT
Unit-VI
Regulation: R11
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.
2013-14
LESSON PLAN
Unit-VII
Regulation: R11

Unit
Session Teaching
No Time Ref Method
Aggregate planning – need and importance. Class room

lecture,
40 T1,T2
OHP,
seminars
Methods of Aggregate planning Class room
lecture,
41 T1,T2
OHP,
seminars
Worked out problems on Aggregate planning Class room
lecture,
42 T1,T2
OHP,
seminars
Line balancing need and importance Class room
lecture,
43 T1,T2
OHP,
seminars
Problems on Line balancing Class room
lecture,
44 T1,T2
OHP,
seminars
Problems on Line Balancing Class room
lecture,
45 T1,T2
OHP,
seminars
Chase planning, expediting Class room
lecture,
46 T1,T2
OHP,
seminars
Control aspects Class room
lecture,
47 T1,T2
OHP,
seminars
Revision of the unit and solving problems of previous question Class room
lecture,
48 paper T1,T2
OHP,
seminars

1.D,E
2.
3.
4
2013-14
ASSIGNMENT
Unit-VII
Regulation: R11
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.
2013-14
LESSON PLAN
Unit-VIII
Regulation: R11

Unit VIII
Session Teaching
No Time Ref Method
Dispatching and its importance Class room

lecture,
49 T1,T2
OHP,
seminars
Dispatch procedure and activities in dispatching Class room
lecture,
50 T1,T2
OHP,
seminars
Reasons for existing functions Class room
lecture,
51 T1,T2
OHP,
seminars
Types of follow ups in dispatching the produce goods/services Class room
lecture,
52 T1,T2
OHP,
seminars
Computer applications in PPC Class room
lecture,
53 T1,T2
OHP,
seminars
Revision Class room
lecture,
54 T1,T2
OHP,
seminars
Revision Class room
lecture,
55 T1,T2
OHP,
seminars

1.B.H.J
2.
3.
4
2013-14
ASSIGNMENT
Unit-VIII
Regulation: R11
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
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

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2013-14

a) Percentage Pass 100

3.1. X Continuous Assessment Examinations (CAE 1, CAE 2)

3.2. X Assignments / Seminars

3.3. X Mini Projects

3.5. X Term End Examination

GUIDELINES TO STUDY THE SUBJECT

On completion of this Subject / Course the student shall be able to:

S.No. Objectives Outcomes

Study of scientific methods of forecasting of the demand of a product.

Explanation of the need of Inventory Management in a production oriented

Examine the Technique of Line of Balancing to monitor the progress of

Examine the method of preparation of Line Balancing to identify the lean

. Study the procedure of despatch of products . Types of follow up action.

The expected outcomes of the Course / Subject are:

S.No. General Categories of Outcomes Specific Outcomes of the Course

To estimate the demand forecasting of the products by

Understand the objectives of production planning &

Evaluate the schedules for machines and manpower,

Understand the high profile concepts like MRP, JIT and

Comprehend the demand forecast requirements and

Understand the software programmes on ERP and

Study of practices relating to PPC in other

Understand all latest modules in implementing

Objectives – Outcome Relationship Matrix (Indicate the relationships by  mark).

Duration (Date) Total No.

Forecasting- Importance of Forecasting – types of

Inventory Management- Functions in inventory –

UNIT - I Regulation: R11

Objectives & References

SCHEDULE OF INSTRUCTIONS 2013-14

UNIT - II Regulation: R11

Objectives & References

UNIT - III Regulation: R11

Objectives & References

UNIT - IV Regulation: R11

Objectives & References

UNIT - V Regulation: R11

Objectives & References

UNIT - VI Regulation: R11

Objectives & References

UNIT - VII Regulation: R11

Objectives & References

UNIT - VIII Regulation: R11

Objectives & References

Completed all the topics specified in the syllabus and

Completed all the topics specified in the syllabus and

Completed all the topics specified in the syllabus and

Completed all the topics specified in the syllabus and

Completed all the topics specified in the syllabus and

Signature of Dean of School Signature of Faculty

Signature of Dean of School Signature of Faculty

Date: 28.2 to 3.2.14

. 1.What is the Material resource planning ? What is its purpose?

3.What is ERP? What are the main features?

4.Define scheduling and what are its objectives?

5.Desribe a) Master scheduling and b) production scheduling.

7. what is PERT and CPM

8.What are the objectives of CPM and PERT?

Signature of Dean of School Signature of Faculty

TUTORIAL SHEETS - III

1.Describe the relevant cost components in aggregate planning.

2.What is line balancing? What are its objectives?