Production Planning and

Control
Production Planning
WHAT?
 Production planning and control address a fundamental
problem of low productivity, inventory management and
resource utilisation.
 Production planning is one part of production planning and
control dealing with basic concepts of :-
 what to produce,
 when to produce,
 how much to produce, etc.
 It involves taking a long-term view at overall production
planning.
Production Planning
OBJECTIVE

 To ensure right quantity and quality of raw

material, equipment, etc. are available
during times of production.
 To ensure capacity utilisation is in tune with
forecast demand at all the time.
Production Planning
WHY?
A well thought production planning ensures
that overall production process is streamlined
providing following benefits:
 Organisationcan deliver a product in a timely
and regular manner.
 Supplierare informed will in advance for the
requirement of raw materials.
 It reduces investment in inventory.
 Itreduces overall production cost by driving
in efficiency.
Cont…
o It ensures that optimum utilisation of production capacity
is achieved, by proper scheduling of the machine items
which reduces the idle time as well as over use.

o It ensures that inventory level are maintained at optimum

levels at all time, i.e. there is no over-stocking or under-
stocking.

o It also ensures that production time is kept at optimum

level and thereby increasing the turnover time.

o Since it overlooks all aspects of production, quality of final

product is always maintained.
Production Planning Strategies
 Production planning takes care of two basic strategies:-
 product planning and
 process planning.
 Production planning is done at three different time dependent levels
i.e.
 long-range planning dealing with facility planning, capital investment,
location planning, etc.;
 medium-range planning deals with demand forecast and capacity
planning and lastly
 short term planning dealing with day to day operations.
 Planning process is a fundamental function of management and should
result in the best possible degree of need satisfaction given the resources
available
Production Control

 Production control looks to utilise different type

of control techniques to achieve optimum
performance out of the production system as
to achieve overall production planning targets.
Therefore, objectives of production control are
as follows:
Regulate inventory management
Organise the production schedules
Optimum utilisation of resources and
production process
Production Control Benefits

 The advantages of robust production control are as

follows:
Ensure a smooth flow of all production processes
Ensure production cost savings thereby improving
the bottom line
Control wastage of resources
Itmaintains standard of quality through the
production life cycle.
Functions of Production Planning
and Control (PPC) Department in
Apparel Manufacturing
By Prasanta Sarkar
• (IM) Job or Task Scheduling: Preparation of time and action calendar for each order from order
receiving to shipment. The job schedule contains list of tasks to be processed for the styles.
Against each tasks planner mentions when to start a task and what is dead line for that task.
Name of responsible person (department) for the job is being listed. For example, scheduling
planned cut date (PCD), line loading date.

• (PPC) Material Resource Planning (Inventory): Preparation ofMaterial requirement sheet

according to sample product and buyer specification sheet. Consumption of material (fabric,
thread, button, and twill tape) is calculated and estimated cost of each material.

• (PPC) Loading production: Planner defines which style to be loaded to the production line and
how much quantity to be loaded.

• (IE) Process selection & planning: Processes needed to complete an order vary style to style.
According to the order (customer) requirement PPC department select processes for the orders.
Sometime extra processes are eliminated to reduce cost of production.

• (IM) Facility location: Where a company has multiple factories (facilities) for production and
factories are set for specific product, planner need to identify which facility will be most suitable
for new orders. Sometimes there may be a capacity shortage in a factory, in that case planner
need to decide which facility will selected for that orders.
• (PCosting) Estimating quantity and costs of production: Planner estimate daily
production (units) according to the styles work content. With the estimated
production figure, production runs and manpower involvement planner also
estimate production cost per pieces.

• (PPC) Capacity planning: PPC department plays a major role during order
booking. They decide (suggest) how much order they should accept according to
their production capacity. Allocating of total capacity or deciding how much
capacity to be used for an order out of total factory capacity. Regularly updating
factories current capacity (production capacity).

• (Automation) Line planning: Preparing detailed line planning with daily

production target for the production line. Most cases line planning is made after
discussing with production team and Industrial engineers.

• (PPC) Follow up and execution: Whatever plan is made is executed by PPC

department. PPC department keeps close look whether everything is progressing
according the plan. Chasing other department heads on daily basis to keep plan
on track. They update order wise completed tasks on the Time & action Calendar.
When they found something is going to be late they expedite and create an alarm
about the delay.
Manufacturing planning and
control.