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    PPC Unit-1

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    Vinay Injam

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    © All Rights Reserved
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    yg at, Define PPC. What are its objectives? oR Define Production Planning and Control. (ode! Paper, Ga) Apri, Set, a (Refor Ont Topic: Proto Plait oh Cota OPROD: OR Define PPC : Apia 19, S02 1} (Refer Only’ Topic Prbdhiction Planning aid CORPOLCEPE)), “ oR ; What are the objectives of PPC (Refer Only Topic: Objectives Of PPC) OR List the objectives of planning and control (Refer Only Topic: Objectives Of PPC) Answer : Production Planning and Control (PPC) ‘ Production planning and control may be defined as the coordination of the series of functions will economically utilize the plant facilities and regulate the orderly movement of goods during the srom the procurement of all materials to the shipping of finished goods at & predetermined Objectives of PPC The following are the objectives of PPC, 1 To attain the highest degree of customer satisfaction and least cost by: customer at the required delivery schedule. 2 ‘To make optimum utilization of resources. 3. To assure that the quality products are produced. 4. To sustain the optimum level of inventory. fe To sustain the flexibility in manufacturing operations, _ EEE Q2, Write the scope of production planning and control. ion System ewer: tent Producti rts a emi jn involves an interrupted fl The scope of production planning and eontr eat Be This praduction system Inv roduetion fg a wanes ‘of material PRODUCTION PLANNING. ano CONT Sstem 1 through the plant. Int pot (JNTU-KAKINADA} classified into two types, 1, Market Forecasting classified as a setion System PPC communicates with marketing department to find (a) “Fob Shop Production SY" ‘out the product's magnitude and delivery details, (b) Batch Production System: roduction System Continuous PC makes a contact with purchase department for 1, Procurement of input ia Gn efficient inanner. It plans the Tis production system Procurement of spare parts and raw materials in the right want atthe ight ime, dn the ight Source and atthe right | SON E wolves continuous or physical low of material. Continuous production continuous physical flow Mass Production System 3. Human Resource Planning @. (by _ Flow Production System. < PC contacts HR departmer ning and welfare of labour, ind formulates a plan for HR Pic 4 Lay ¢ Planning {a) Job order production. AC Provides the in ‘based on which the plant layout made, “Jso the plant iayout is executed by PPC. ib) Batchiproducton 5. Method Selection | ex PPC help inthe selection ofestpstod ofproductin | __Whatisjob order production? spanayt other available alter @3. What is production system? List out various Production systems, oR What is Batch Production? What aro the various types of production (Rerer Ons To: Banc Proton, systems, (ode Peper ata) Anentny-9.Set4.010) | Answer : : (Refer Oniy Topic: Tipes of Production System) (8) Job Order Production oR List out diferent types of Production, Production. The 7 Jeb shop production sy | Antofar S03,0N8) | producing the products for coeae di {Refer Oily topic: Tapes oy Brocieon Sisiemy “Sauirements. In this system, all the ae roceses and diferent sequences of What is continuous production? ©) Batch Production ses cab Inthi i Refer 29 Tope: Continuous Pradvenon Seiten), 'styPe of production, ewe « ih id : Se manicured into ie ae Answer + ‘Aorintey*7 84, QN6) | Different products ane, noo Bate Nt products are man, Production System on receipt of orders, (4 production system converts some inputs like men, ‘material, money et into usefl Output like fnished produets and services) he transformation of input into outputs achieved through the production system, Look for the SIA 1.3 pics tis eceeee UNIT-1_ Introduction Job Order Production and Batch Production System Ge._List out the differences botwer Answer # Job Orde Production and Batch Production System can be differentiated as follows, va Baten Production Order Production 1 | standard machineries ar installed depending on whether | Special purpose machineries are installed. the factory is engaged in light, medium or heavy, engineering. Similar machines are amanged Diferent machines may be grouped Cost and time equ Yo make praust willbe high, | Operation time and total time to make prot will be | satiny. 4. | Work in progress will be high. Similar to job production. s. | Requires standard material handling equipment Requires special purpose handling equipments. 6. | Requires special supervision. Similar to job production. Examples: Machine tools, furniture, pharmaceuticals etc: Q6. What are the applications and examples o° batch shop production. =. = ” Examples : Ship building, civil engineering etc Amwer Applications of Batch Shop Production sch production is applied in either ofthe following situations, \When quantity of ouput nereases leading to repetitvenes \When there ae Auctuatons in market demand aros the yea, Batch production system is commonly followed in bakeries and in manufacturing | of sport 3 Examples of Batch Shop Production F Some ofthe examples of batch production are paints, clothes, drugs, sheet metal pressers, 7 eee ‘Refer Onl Topic: Applications of Mass di ahi »\ adi fn nian Answer Mass Production System When difierent parts or assemblies are manufactured with the Kelp’ 6f a6 Production, fi) wpa Applications of Mass Production System The concept of mass production is applicable fo diferent (pes chemicals) to disrete solid parts (hike f ow ol agreed vee aie ful, food, mined mineral aD and houschold appliances). Example of Mass Production System™ Components of industrial prodets; SPECTRUM ALL-IN-ONE JOURNAL: Q8. Define production. Discuss about production planning oR and control. (os What Is PPC? What Is the need for PPC? ies sor PPO) (Refer Only Topics: Pro agi Cnt (PPC) tore” - * tem. stem. Explain the Importance of PPC department In a typical production sy (Refer Only Topic: ImportaieIN@ed FOE PPC) Aprib18, Set, Answer: Production Production involves a series of operations which convert the material: Production Planning and Control (PPC) : ai : 1 series of functions according to @ p “Production planning and contro! may be defined as the coordination of th c : will economically utilize the plan facilis and regulate the orderly movement of goods during the entire manufacturing from the procurement ofall materials tothe shipping of finished goods ata predetermined rate”. i from a given form to a desired form. Production planning and control comprise the planning, routing, scheduling, dispatching and follow up productive process, so organized that the movement of material, performance of machines and operations of I subdivided are directed and coordinated as to quantity, quality, time and place. It is based on the principle “plat work your plan”. ‘ Production planning and control is the foremost activity of production process wherein firms make the materials and physical facilities so as to optimally achieve the pre-determined objectives. It involves the pl and coordinating activites. 1 Importance/Need for PPC ‘The importance or need for production planning and control can be made clear through the 1. | Production planning and control helps in planning purchase of i es ani ote ual tet fe pt ee pe 2./_Ithelps in setting performance standards for employees as well as equipments, 3./__Itmakes sure that the resources available in the organization are utilized to their 4,/ It aims at manufacturing quality products within the budgeted cost and time, 5./ Routing, scheduling and dispatching are the important functions of production planni mn 6. PPC process involves regular inspections and these inspections enhance the perf i processes. Ithelps in selecting one best processing technique from the numberof alternative 1 ensures flexibility in production related operations, Introduction To attain thi degree ofc customer at the required delivery schedule, utilization of resources. To make optin products are produced that the quali To assu 4 Tosustain the optimum level of inventory. 12 operations. s.~ Tosustain the flexibility in manutfact 6, Tomake sure that there is effective reduction of cost and cost control Aective result for least total costs > Toensure &Toprevent and stop the barriers of stages of production 9. Tosolve the production problems, 10: To increase the coordination between different departments, labour and machines. 11” To increase the profit levels of the firm. To retain the stability in production system. 13, To-make sure that the demand is forecasted in proper manner; 14. Tocffectively carry out the optimum utilization of inventory. 10. “Production planning and production control are the two basic functions of PPC” Explain. ok 4 901 Define Production Planning. State its objectives. List the information required (Refer Only Topics: Production Planning, Objectives of Prodilétion Planning, OR Discuss the objectives of production control. (Refer Only Tope: Objectives of Production’ Control) OR Discuss the objectives of production planning. (Refer Only Topic: Objectives of Préchiction Planniig) Answer : The two basic functions of PPC are, Production planning and 2. Production control. Production Planning Production planning is the function concerned with planning, directing Products and the way ee the production facilities buildings, machines, ‘valable for production”, « Production Planning is concerned with deyeloping spe Objectives of Production Planning Following are some of the objectives 6f production p To evaluate the nature of resources sugh as men, mat bitch 1.6 Information Needed for Production Pl ling The following inform: planning jon is needed for production (2) Theresourves that are useful for production sich as labor material ete ii) Demand forecasting in prospect of planning, ii) Teneeds authorized subcontracting quantity and back onder level iv) Starting and necessary ending inventory, 2. Production Control Production control refers to the various control techniques used to achieve performance according to the set plans. Production control coordinates different resources. Itaims, at chieving production targets, increased profits, optimum use cof available resources, better quality and more economic goods. The production control regulates and controls the different ‘ssis/operation of production process for orderly and smooth Objectives of Production Control ‘The objectives of production control are, To optimize the use of production resources, To develop contemporary standards of production, To ae accurate production cost controls, Q11. Write about the scope of production planning and control, Answer : Aor, St3, a4) The scope of PPC can be understood from following points, 1. Market Forecasting PPC communicates with marketing department to find ‘out the product’s magnitude and delivery details. 2. Material Planning PPC makes a contact with purchase department for procurement of input in an efficient manner. 'It plans the Procurement of spare parts and raw materials in the right quantity, at the right time, from the right source and atthe right place 3, Human Resource Planning PPC contacts HR department and formulates & plan for HR Planning and welfare of labours 4, Layout Planning PPC Provides the inputs based of which the plant layout PRODUCTION PLA TU-KAKINAD,y ninG AND conTROL lI tection Method S he selection of best method of producti jable alternatives: ppc helps int from many other ava" 6. Inspection ppc communi lates a plan for continuo tes with quality department gy iat ous inspection across producti form process 7. Process Plans ingthe best sequence of is and fixtures. It sets es of time schedules for df PPC helps in ascertaiit and in planning for jigs, tool standards for the establishment stages of production. stions of production Q12. Define the functions yh control. rere rT OR. List out the planning functions and functions separately, explain them | oR and control. Answer b are broadly categorized into two following figure, is made. Also the plant layout | geuted by PPC. 1 Introduction’ UNI Routing It's the process of deciding the order of operations t0 secaried out during the production process. ascertains as 10- ‘hat work should be carried out? How these operations wll be Nrformed? And where these operations would be performed? {cs main objective is the selection of best and cheapest Way to perform job (Scheduling It includes giving priorities to different jobs and ascertaining the starting and finishing time of each operation! activity. Scheduling basically lays down the preparation of times tnssed schedule, which shows the time and rate of production (@) Loading Machine loading is performed along with routing to ensure the smooth workflow while fixing the loads to different machines jobs priority and machine capacities are considered. Scheduling enables the firm to be aware ofthe delivery dates for production of parts, sub-assemblies and finished products. Tt also used to maintain uniform load on different work centers, and machines. (©) Sequencing Sequencing involves the determination of the order in which the operations/jobs are processed, Problems may arise the work centres are heavily loaded and the jobs are lengthy. re, processing the order is very important with respect to idle time cost and waiting cost Theref Production Control Functions The following are the production control functions, Dispatching A Its related to the actual performance of work through planning process where the/instructions are delivered as per t! equences shown in the route sheets and machine sdules. Based on their information, orders of raw. materials can be dispatched to the desired site. (b) Expediting/Progressing Keeping a track on the production activities for ensuring that the activities are performed as per the schedule is known 8s expediting. It follows dispatching function, (Follow-up } Follow up is one ofthe stage of production control which involves the conversion of plans into actions. (4) Anspeetion It constitutes checking the quality of production process, ‘analyzing the effectiveness of process, methods and workers, So that desired quality can be achieved by making the necessary improvements in the process (@)_ Evaluatin “The entire process of manufac the necessary improvements wherever ‘Control of various activities like waste reduction, analysis, inventory control and optimal exploit so as to reduce manufacturing cost. 13. Explain the relationship between ‘Production’, ‘Planning’ and ‘Control’ Distinguish between production planning and production control. Explain the relationship between ‘Production Planning’ and Control. ‘Apiay 17, St, 240) Differentiate between Production planning and production control. id Corrective A‘ scturing is evaluated to make they are required. value ofresources oR ided to different the data is provi Jon cont 1. ] Under production planning, the information relating to adel ear different essential inputs is collected and maintained. prociee) es 2..| It involves the preparation OF paper work and otber It involves forms Production control is @ atshop floor. Its functions in actual use of paper work and necessary forms, It is centralized activity and is carried out in office, Its functions include process planning, job scheduling and materials planning, Remedial action is taken whenever there is a failure What are the phases/stages of PPC? Explain. diffused activity. It is carried out ‘clude expediting, progressing OR Describe the activities in follow up or control phase of PPC. (Refer Only Topic: Control Piise) oR What are the activities in control phase of PPC? Explain in brief. (Refer Only Topic: Control Phase) Answer : Following are three stages/phases involved in PPC, 1. Planning phase 2. Action phase and, 3. Control phase. : Planning Phase in which firms are involved in forecasting the a ase, production needs are determined along with the: and so on. Planning is essential for carrying out all the production activities ina Planning phase includes two types of planning, ‘ou (Prior Planning [Pre-production Plan} {Wincludes all the attempts done before the initiation of active planning like produc. ‘aggregate planning, master scheduling, order writing, MRP and soon, Ps Ust develo Active Planning [Actual Production Planning] |timmediately follows the prior planning and includes all those tasks which, Decisions related to process planning and routing, this type of planning. 2. Action Phase 11 constitutes a follow up stage of planning phase. In this actual . which includes a crucial scp ofdisptching, ‘manufacturing of the Dispatching is a process of transferring the materials or other product Products, Dispatching ake place through the job order, store issue onder, tool orden (Job Order Its the crucial number specifically alloted to each item and is valid in (i) Store Issue Order r It places the order with stores to issue the specified material that the product specifications. (iii) Tool Order Base on he toed hea wom roves eeu oo eet fry Look for the SIA GROUP LOGO QB ‘on the TES Gi) are directly related ‘materials planning, tools planning, al thee 6 required for Smooth | UNIT-1_ Introduction Ticket Time ticket is a card official which records the tit ° Saat 1 and testing the various processes of As the name indieates, through this oficial instructions are given for inspect ee A ne Instrctions must be flowed by the various departments fr mit imizing the cost overheads of rewor ai) Move Order . towards the production site. The timely movement ichelps in moving the aw material, components, spares, sub-assemblies ae helps in overcoming the delays in processing, thereby ensuring the quick fulfilment of orders, Control Phase inthis phase, necessary guidelines are provided tothe production manage inthe form of feedback which help in the gestive control of production activites. It contains two major activities, (a) Progress Reporting i tthe sub-phase, data related to the current status of work s determined which can be compared with the pre-set standards; ‘he data related to material ejection process variations, equipment feilure, operator efficiency, operator absenteeism $0 Gnare collected and analyzed through variance analysis, Such analysis is used to recognize the critical areas which need io be controlled by taking corrective actions. (o) Corrective Actions : . Corrective actions are mostly sudden and situational and are taken to overcome the problems encountered in reporting: orogress. It inchudes the following activities, 5 Creating Schedule Flexibility, tiene aa ‘Because of some unexpected reasons ifthe pre-planned schedule is not met, then some’adjustments need t0 be made to make the schedule flexible, 5 . Capacity Modification Capacity has to be modified depending upon the demand. If these exists variation in demand then to be changed based on the variations _ Make or Buy Decision 4 \When the decisions related to “Make or Buy” of a produet are failed then they should be fe-exam decision which is most appropriate for firms should be made. al Expediting the Work j Whenever the results ofthe progress report are not in accordance with the set targets, taken, 3 Replanning i ‘fthe expediting is failed to bring back the desired results as per the standards, then be redesigned. : Product design and development Process design Work centre design Factory layout je |e Sales forecasting Technology adaptation Equipment selection }@ Change in capacity / Pre-planning production ate Preplanning = ee 1.10 propucrion PLANNING AND CS 7 1.3 ELEMENTS oF PRODUCTION CONTRO oon a Q15. Explain various elements of production control. an py 16, 502,010) ‘What about elements of production control in detail? . ‘oR Discuss about different elements of PPC. Answer: ‘The various elements of production control are, (Control of materials Gi) Control of planning Gil) Control of manufoc ng capacity ()_ Control oF tooling (9) Control of quantity (vi) Control of activities (vii) Controt of due date (viii) Control of material handling and Gx) Control of information. (Control of Materials [Cinvolves the control of inventory. It provides the information for issue of materials to the shop and also the’ of materials within the shop. y Gi) Control of Planning assures, (a) Receipt of latest forecast data from sales and production planning (b). Routing information from process engineering and (©) Bill of material data from product engineering, (ii) Control of Manufacturing Capacity finds he availabilty of bout and equipment apates and sue realistic production of recording completed production (iv) Control of Tooting : Irinvolves, checking the toling availability nd isuing of tools fom ool cribs to () Control of Qua This involves follow up of progress of production, so as to ensure that the Also to ensure that corrective action is initiated where work fails to pass cach inspection st (Control of Activities igtakagl It involves, release of information and order at asigned time, it (vil) Control of Due Date 11 involves, checking the relation of actual and planned seule od scheduling of work assigned to every machine, (viliy Control of Material Handling It includes, releasing orders for movement of work to ensure, availability, of (ix) Control of Information It involves, distributing timely reports and information prs ait taken. Also for future planning, providing data on production performance, Look for the SIA GROUP 11 49, St3, ane) Discuss the benefits of production planning and control. Nae z (cfr Only Tope: Aadantoges of PPC) oR ’ State advantages of better production planning and control. y Topic A (Refer Only Topic Advantages of BPC) Ne aces Answer ¢ advantages of PPC The advantages of PPC are as follows, Production planning and eontrol is one of the most important functions of operations management and is considered as the heart of operations management which co-ordinates different stages of production, Effective and efficient production planning and control leads to optimum utilization of resources, Best quality, less ‘manufacturing cycle time, lower inventories, quick and easy delivery, lesser production costs, lesser amount of capital iment, better customer service and greater customer satisfaction, . ‘and economical produetion on time, right With the efficient utitization of resources, it leads to increase in product quality of goods with right cost would result in higher customer satisfaction, : Smooth funetioning and proper work-flow can be ensured with the plant facilities when there are less nlumber of machinery breakdowns. This would further reduce the idle time of labour, machinery and equipments. Thus increasing the morale and discipline by an employee, Productive PPC helps the firm to increase its total retumns, market share, profitability. #6 Ic helps the firm to face the competition by maintaining stable inventory levels, best quality, stability and reasonable or affordable prices. Disadvantages of PPC The disadvantages of PPC are as follows, The assumptions and forecasts made in production planning and control may not be acurate sometimes. regarding availability of raw materials, customers demand and plant and equipment: z 2. Routing and scheduling of big and complicated products is difficult task and involve a Fluchustions in production levels based on prodliction plansmnsy wet bee eopkett aaa Effective production planning and control is not possible in circumstances where environment. Like changes in customer taste, preferences and habits, changes in technological changes, inadequate power supply, uncertain natural problems like, war, a peepee eerecams 1.4 TYPES OF PRODUCTION, 017. What do you understand by a production system? What are its vario production sysem. oR ifferent types of production system. aia i 220 Ey Describe the ‘Refer Only Topic Types of Prodiction Siem). oO te the pro oR au tala Explain various types of production system with examples ./. ) (Refer Only Topic: Types of Production System), tse dn naming Explain about functions of production system (Refer Only Topic: Functions of Peoden@n Sisfem@ Auewert ished products ‘outputs like fins! ang Produstion System it, money te into seh oT aduction systems show A prediction tm comers some inp ie men, meri, services) The transformation of input into outputs is achieved throug! in the figure, Departmei Customer (TQM concept) e ° © e s Figure: Production System ‘Types of Production System Production system can be classified into two types, Production System Tnermient ~ Continuous Production System fie shop Production System Batch Production System 1. Intermittent Production System “Intermittent production” involves an interrupted flow of material through the purpose machines are usedIt produces the items which ae diffrent in nature andi Intermittent production i classified as, (@) Job shop production system and (©) Batch production system, Job Shop Production System ‘The job shop production system deals with producing the products this system, all the orders need different processes and different {gb shop production system ye fulfill the requirements of customer's onde 8 repair shops and other small (b) Batch Production System nie In this type of production, two oF more types of products are manufaen erent products are manufactured and stacked and then sold on receipt of ‘This is generally adopted in medium size enterprises Iti the stage in Pigger in scale than re Production while ii smaller than that of macy Example: Drugs, painls, clothes, forging machines, sheet metal pressers, 2. Continuous Production System : Continuous production system involves continuous of slmost continuous system uses special purpose machine) It produces the standardized components (@) seo Introduction ion is classified a Mass Production System, 11. Flow Production System. Mass Producti When diffe production) In this type of production, mi ‘ery lange Wolume of production, Mass production followed by all outputs System 1s, then it is known as mass and it involves @ this Ip of a continuous proce the form of a line of product layout 1d process standardization and similar pal parts or assemblies are manufactured with the hel ines are organized in tl eludes both produet ans ‘Example: Components of Industrial Products, on System, Flow production system deals with continuous physical flow of materi: rate and has continyous demand, trol, Chemicals and automobile plants, Functions of Production Systems Flow Prod iy is used when the prodiet has fast consumption Fxampk The proluetion system is broadly classified into two types, 4, __ Intermittent Production System Intermittent production system is sub-classified into two, . (i) Job shop production system and (ii) Batch produetion system, Functions of job shop production system and batch production system are as follows, (2) Job shop production system deals with manufacturing the products for fulfilling the needs and’ requirements of customer, it (b) Batch production system deals With manufacturing two ot more products in batches at regular intervals. 2. Continuous Production System Continuous production system is sub-classified into two, ee (i) Mass production system and (ii) Flow production system. The functions of mass production system and flow production system are as follows, ~~ (2) Mass production system deals with manufacturing | different parts or assemblies: (b)__ Flow production system deals with production of products with continuous physi Q18. List out the characteristics of different types of production systems. Answer 1. Characteristics of Job Shop Production System ‘The main characteristics of job shop production system are as follows, () Small Production Runs It manufactures one or few number of single designed product strictly (ii) Flow of Materials watt a There is highly discontinuous flow of materials and components at different operation-wise work content. (iii) Manufacturing Cycle Time ‘The manufacturing cyele time is lengthened due to long delays at (iv) Layout of Plant and Equipment rocess-type layout is used in these production systems as there product, Pi Rl Cost of Production ‘Phere is high cost involved per unit of production because the firm, automation, SPECTRUM ALL-IN-ONE JOURNAL FOR ENGINEERING ST" NUE OL p CONTR | = PRODUCTION PLANNING. AN ; : 2. Characteristics of Batch Production System “The characteristics of batch production system are as follows, (i) Produetion in Batches 1 order procured Articles are manufactured in batches as per the specifi Gi) Division of Labour Division of labour is possible i) Flow of Materials Flow of materials is imermittent (iy) Plant Layout Plant layout is of process type (©) Maintenance Proper maintenance of machinery and equipment is eset 3. Characteristics of Mass Production System ‘The characteristics of mass production system are as follows (© Production in Large Volumes Production is carried out in large volumes. (i) Short Cycle Time ‘The eyele time of production is short. (ii) Machines and Equipments special purpose machine are wed which have the higher production eapactes an output x (vi) Flow of Material wen Materials, components and parts have continuous flow without any backward mi Handling (viii) Materi Material handling is carried out automatically, Characteristics of Flow Production System The loving unt nic 6 Ooms a rare tne Sow proacton ye rads pas css (ii) Material Handling ? aulreahaaay fang of mae done all ey ee faeces The upeu of be pan dese ante cee cn cconbpineasad () Maintenance Proper maintenance of GH9. List out the advantages and disadvantages of different productio, Answer 1. Advantages of Job Shop Production System The following are the advantages of job-shop-produetion systems, Look for UNIT-1_ Introduction Tr requires small amount of investment in equipments and machinery It is flexible in nature and ean be stated early. process. one operation, does not interrupt the whole inthe job shop system, a mistake or defect ihe rick involvod is Tess and the chances of failure are also Tess piadvantages of Job Shop Production System Job shop system has the following disadvantages, “rhe production system of jab shop system is very complicated. ‘he job shop system faces difficulty in loading the machines. te requires high inventoties, ‘he cost of material handing involved in job shop system is high. Advantages of Batch Production System Batch production has the following advantages, Plant and machinery ae optimally utilized. . 5 When compared to job order production, cost per unit in batch production is less. : tn batch production, investment in plant and machinery is also low. patch produetion i flexible in nature to follow any process and number of products 5. Operators enjoy greater job satisfaction ‘ pisadvantages of Batch Production System - Following are the disadvantages of batch production, 3 Due to irregular and longer flows, material handling i difficult. 2, Production planning and contro is also complicated in batch production. 5. Due to repetitive modifications in setup, it results in higher setup costs- ei dd «Workin process inventory is higher when compared to continuous production. IIL, Advantages of Continuous/Flow Production System Following are the advantages of flow production system, 4 In continuous production system, the production planning and controls simple ‘when compared itimakes us of specialized machines and procedures fr standardizing the items in large quan Ifthe management takes the decision fr discontinuing particu ine, then same other article. 4, Material handling is minimized. 5. Ithelps in providing lowest production cost pet unit, Disadvantages of Continuous/Flow Production System “The following are the disadvantages of continuous production system, Ai ft} roduction systems depends on effestive 1. The effective working of continuous pt control ; 2. Incontinuous production system, the managers have to spend signifiant efforts for ‘As continuous production system makes use of specialized machines, the is very high. fe + IV. Advantages of Mass Production System Mass production has the following advantages ————— CF KAKINADA} 1 [UNTU: 1.16 PRODUCTION PLANNING AND CONTROL = 1 © of production is high in mass production with less eyele time. smiskilled or low skilled ion ofthe capacity with the help of line balancing. 44 out withthe help of 5 3. Mass productio does n workers require high skilled workers, it can be ca 4. Less manufacturing cost pe nit Disadvantages of Mass Production System Mags production sulfers from few limitations, They are as follows, alt. hine stops functioning, then the entire production line would be hi 2. Alteration in the product design would drastically alter the line layout. Huge investment in production facilites 4._Inmass production, the cycle time is ascertained with the help of the slowest openton a 220. Write any seven different between job shop, batch type and continuous pr a a tem? What are the differences among job shop, batch type and continuous production sys Answer : The various differences among job shop, batch type and continuous, Criteria Job Shop Batch Type 1. Meaning The job shop production system | Batch production is a type of| Continuous production that involves production of one| production process in which the | refers to the flow of asi cr few quantity of products that | job in lots or batches pass through are designed and produced as per | various functional departments. customer requirements 2. Flow of There ishighly discontinuous flow | The flow of materials intermittent. Material of materials Quantities Jt Manufactures one or few] A whole univbatch of products are Produced | numberof single designed product | produced. strictly according to customer's specification ‘Types of | General purpose machines and] Spesial purpoie imac Machines | facilities are used. ‘employed. Bras 5. Example Tulor's shop, vehicles repair shop | Production of Drugs, and other small workshops. clothes, forging machines ete. Mult-skiled workers are employed | The workers should be skilled and versatile, ! 5 7. Variety of | There ae infinite vvietyof | Thee are many variety of Products products arity of products 5. Types of Customized Vibe | Product 9-Advanaes: | poids good comin | eres Ret, gatiy ag | os | 10. Disadvantage | It is expensive and non-repetitive Introduction UNIT- 4,5 ORGANIZATION OF PRODUCTION ORGANIZATION ee row 21. What is the purpose of manufacturing organization in an ind Drawa 2 a ‘manufacturing organization. Also, Explain the role of PPC ina ‘manufacturing company. oR state the purpose of a manufacturing organization In an industry Give a typical organization structure of a manufacturing organization. (Refer Only Topies: Purpose of & Manfactuelhg, ‘Mamdacturing Organization) cs aes OR Discuss the organization structure of production, pI zefer Only Topic: Typical Organization Strichire Bf OR Janning and control department Aganter-#8,Set2/<20) With the help of an organization chart explain how PPC department can carry-out Its functions. Ma nen one Sot Manufacturing Company) eno ‘oes Set, ts) OR ‘ Describe in brief, planning in manufacture organization. ‘Refer Only Topic: Role of PPC Déparinient ia Manufactiriig Come) Answer ? Purpose of a Manufacturing Org: The purpose of manufacturing organization is as follows, iciency in the production planning and control. rations. = janization in an Industry To bring manufacturing effi To help the organization to automate various manufacturing ope To manage the organization production capacity 4. To manage modes of manufacturing, types of job costing ces for training and development. and design of product features. 5. Toallocate sou To increase product quality at every stage of production lin. To meet the customers expectations and reduce wastage. {spical Organization Structure of a Manufacturing Organization aaarving igre shows the pial incur of a manufcturing organization andthe ole af [Plane Manager Manufsturing | . Role of PPC Department in a Manufacturing Company rs Moore, the functions of production planning and it serves in coordinating the activities of vklin has also pointed out that production control is s breathing, when simple repetitive nd in the plant, when less repetitive According to Franklin G. with human organism nervous system. muscular movements. F as the nervous system regulates one” ation. Itis ‘an organiza lis Fraetion Planing and Control (PPC) play an important role inam OTeaNZAT yy decides what, when, where, how and how much will he produced. This depart ‘Therefore, itis essential to carefully organize the PPC department. ‘The organization structure of PPC changes from company to compat acturing method, type of industty, needs of industry, layout of plant division. The hea ly, PPC department is organized as a part ofthe production d to te chief of man Gene turing ie, production manager ay be appointed t0 Carry Out th self or a person may ing this ‘engaged in performing tof person pnareds of employees. ies, Also, the procedures used are ‘sential du tothe high na small organization, PPC work is carried out by chief executive hi function. PPC function becomes sound in a medium organization and the ume of Increases, In case of large firms, the PPC becomes well-developed department c' cess indust The organization structure is comparatively small in continuous proc se simple. But in case of intermittent industries, elaborate systems of production are Very of products, Q22. Explain the internal organization of PPC Department. Answer : is assigned with different functio Setting up of PPC intemal structure depends on various important consideration. PPC is ass ecrent aca fased on the nature of industry, company size and management policies. Different companies assign

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