A Study of Production Planning and Control

Shivaji University, Kolhapur Production Planning & Control
CHAPTER NO I
INTRODUCTION TO THE STUDY
1.1 INTRODUCTION
Production planning and control involves generally the organization and

planning of the manufacturing process. Specifically it consists of the planning of the
routing, scheduling dispatching and inspection coordination and the control of the
materials, methods, machines, tooling and operating times.
Production planning and control is the organization and planning of the

manufacturing process. Its co-ordinates supply and movement of materials and labor
ensures economic and balanced utilization of machines and equipment as well as
other activities related with production to achieve the desired manufacturing resulnots
in terms of quantity, quality, time and place.
While planning sets out the goals, mission and steps for companies to meet
market demands, control are put into place so that companies can contend with
changes when they inevitably occur. In other words, control ensures that companies
can adapte and change their plans and process swiftly.
A] PRODUCTION –
Production is any activity directed to the satisfaction of other people’s wants

through exchange”. This definition makes it clear that, in economics, we do not treat
the mere making of things as production. What is made must be designed to satisfy
wants.
B] PLANNING –
Planning is the fundamental management function, which involves deciding

beforehand, what is to be done, when is to be done, how is to be done and who going
to do it. It is an intellectual process which lays down organization’s objectives and
develops various courses of action, by which the organization can achieve those
objectives. It chalks out exactly, how to attain a specific goal.
Dr. Ghali College, Gadhinglaj Page 1

C] CONTROL –
Controlling is one of the managerial functions and it is an important element of the

management process. After the planning, organizing staffing and directing have been
carried out, the final managerial function of controlling assures that the activities
planned are being accomplished or not.
Control can be defined as the process of analyzing whether actions are being
taken as planned and taking corrective actions to make these to confirm to planning.
1.2 MANAGEMENT PROBLEM
To examine how Laxmi Poha, Kurmura and Rice Mill does production
planning and control as per the standard of quality and quantity wise.
1.3 OBJECTIVES OF THE STUDY
1] To study the concept of production and control.
2] To study the production planning and control of Laxmi Poha, Kurmura and Rice
Mill Gadhinglaj.
3] To understand the production planning and production analysis of products of the

organization.
4] To give necessary suggestion, if it requires.
1.4 SCOPE OF STUDY
1. The scope of the study was related to Laxmi Poha Kuramura and Rice Mill
Gadhinglaj.
2. The scope of the study was related to Production, planning and control only
1.5 IMPORTANCE OF THE STUDY
1. It is helpful to study the planning of Laxmi Poha, kuramura and Rice Mill
Gadhinglaj production process in deep.
2. It is helpful to study the different production planning process.
3. It studied about production on cost and where to curtain the production cost.

1.6 RESEARCH METHODOLOGY:
This study was base mainly on primary data. The primary data is collected with the
help of Laxmi Poha, Kurmura and Rice Mill Gadhinglaj
Data Collection:
1. Primary data –
1] Observation Method- for this study I observe production process of Laxmi Poha,
Kurmura and Rice Mill.
2] Interview Method – For this study I had taken interview of labour and owner.
2. Secondary data:-
The secondary data was collected mainly with the help of following
Data Analysis Instrument
Research used questionnaire, interview, reports, website, tools for collecting data.
1.7 LIMITATIONS OF STUDY
1 The study is limited to 30 days.
2 The study is limited only production process of Laxmi Poha, Kurmura and Rice
Mill Gadhinglaj
3 Due to the confidential reports the limited and based data is collected.
1.8 REVIEW OF LITERATURE
1. European journal of operational research 1993 production planning and control is

of great importance for the competitive position of manufacturing firms. Forever
thirty years a large number of computer assisted production planning and control
systems have been on offer, most of them based on the well known MRP logic.

CHAPTER NO II
THEORETICAL BACKGROUND
2.1 INTRODUCTION:
An every business organization has mainly four functional areas viz marketing
production, finance and personnel. Production is the basic activity of all industrial
units. All other activities revolve around his activity. The end-product of the
production activity is the creation of goods and services for the satisfaction if human
wants. The production activity is nothing but the step-by-step conversion of one from
of materials into another, either chemically or mechanically this is done in factories
which house manufacturing process. The basic inputs of the production process are
men, farm, sea and forest are used as raw material on which the processing in done to
create or enhance the from utility. It should be noted that the finished product of one
manufacturing unit done not always furnish a eady-made product for the ultimate
consumption In a chain of manufacturing activities, the finished product of the
processor sometimes become the row material for the other manufacturing firm
falling next in the sequence
Production in the other world is a transformation system where inputs, are

converted into outputs. The transportation could be physical (manufacturing),
vocational (transport), exchange-based (retailing) storage based (warehousing),
physiological (hospitals) and information
In short production process is backbone of all manufacturing activity and it is

a continuous process of economic activity which enables flow of goods and services
and there use for satisfaction of human wants. The human wants are ultimate which
keep the wheel of production going

MEANNG AND DEFINITION OF ‘PRODUCT PROCESS'

AND‘PRODUCTION MANAGEMENT:
The word production management arrived first with the emergence if

manufacturing industry and necessity to manage it as such. The meaning of the term
Production Process and Production Management as given below.
Production Process is the sequence of operation that transforms material given

to direct form to satisfy the need of the customer. It is important to give a quality
product at right time, at right place and at reasonable price. For achieving the object
of the essential that the production process is well-managed the factors of production
elements which co-operate which one another in the production process.
Production process is enabling the industry to exploit the abundant natural resources
profitability. The production processes depend upon following factors.
A. Location
B. Plant Layout
C. Type of production system
D. Production Planning and Control
The meaning of the term "Production Management" is certified in the

following definitions:
1) "Production management" is the process of planning, organizing, directing and

controlling the activity of the production function. Production function is the
conversion of row materials into finished products.
2) According to M. J. S. Harry:
"The word production is often used to mean the same as manufacture. In order to go
through a process of manufacturing itself, we need basically three things someone to
do the job, his equipment and the necessary materials to run production, we require
service activities which make sure that the manufacturing activity can go on and
control make sure that it goes in the right direction".

3) According to A.H. Harding:
"Production management concerned with those process which convert the input into
outputs. The inputs are various resources like raw material, men machines, methods,
etc and the outputs are goods and services"
4) According to E.S. Buffa:
"Production management deals with decision-making related to production process so

that the resulting good or service produced according to specifications, in the amount
and by the schedule demanded and at minimum cost".
The definition given is E.S. Buffa is simple, clear and exhaustive. It explains the
following important aspects of production management.
a) It is a decision-making managerial function.
b) The decision are made regarding the production process required for converting the
raw materials into finished products and.
c) The production or output should be according to specifications, in the specified

quantities, as per the schedule and at minimum cost.
2.2 OBJECTIVE OF PRODUCTION PROCESS:
The production objectives are majority divided into two categories.
A) Ultimate objectives.
B) Intermediate objectives.
A) Ultimate objectives:
The primary responsibility of the manufacturing activity is to produce the product or

products at:
1) Pre established cost.
2) According to the specified quality and within the stipulates time.
Thus the ultimate objectives can be sub-classified as under

1) Manufacturing costs:
The unit of the cost should be estimated carefully and every should be made to stick
to the cost standards.
2) Product quality:
The manufacturing organization should try and translate the product specifications
given by the consumers into measurable objectives. It should be noted that the product
quality done not conflict the manufacturing cost and manufacturing time schedule
objectives.
3) Manufacturing schedule:
The time schedule should be set for each and every activity in the manufacturing
process and not only for the major aspects.
B) Intermediate objectives:
Production is the result of various types of inputs like men, materials, machine,
manufacturing services etc. The intermediate objective strives to attain the optimum
utilization of these various type of inputs. The intermediate responsibilities can be
spelled out as under
1. Machine and Equipment:
It includes the acquisition and utilization of machinery and equipment.
2. Materials:
The per unit material cost should be specified and efforts should be to increase the
inventory turnover of all types of inventories.
3. Manpower:
Production activities should be closely allied with the selection, placement, training,
and utilization of manpower.
4. Manufacturing services:
Proper objective should be set for the utilization of important facilities power, water
supply, materials handling etc.

2.3 ADVANTAGES OF CONTINUOUS PRODUCTION SYSTEM:
In designing the continuous from requires a great amount of efforts. But once it sets
going, it offers much simplicity in operation.
i. It has low unit cost per unit production.
ii. The machine operation are simpler Maintains however is difficult and complex
iii. The managerial control simpler.
Disadvantages of continuous production system:
Through cost effective is suffers from following disadvantages.
i. It is difficult to adopt it to a different product line it is also difficult to change the

output rate.
ii. Breakdown results in stoppage of line.
iii Line balancing responds to output rate of slowest workstations. The workers whose
output rate is higher are therefore kept less busy.
iv. The tasks are repetitive and so monotonous now. The process is dehumanizing. It
affects moral of the workers
v. Initial project cost is very high since special purpose machines are used.
Maintenance is also very expensive
Where production is not continuous and is affected by the specific order by the
customer. Under this system no single sequence of operation is appropriate and
therefore standardized machine or materials cannot be used.
The production system can be classified as:
a) Job shop production :
In this system, production is made on the basis of orders of the customers job
production is the manufacture of a single complete unit by an operator or a group of
operator.

Enterprises producing capital goods such as heavy, special purpose machinery

doorplate boilers etc. use this type production system, because specifications of each
order differ.
b) Batch Production:
Under this system production is done in groups or batches on medium scale. As

quantities increase beyond the few made during the earliest history of many
companies, work may be carried out under batch production methods. Such methods
require that the work on any product is divided into two parts or operations, and each
operation is complete throughout the whole batch before the next operation is
undertaken. This technique is probably the most common type of production.
Advantages of Intermittent Production System:
Following are the advantages of Intermittent Production System:
i. It is a trade of between flexibility and efficiency.
ii. It gives us a variety at low cost, since it used general purpose machines.
iii. There is staff advantage since each worker performance a complete operation
giving him pride of workmanship and sense of responsibility. iv. There is high
capacity utilization.
Disadvantages of Intermittent Production System:
Following are the Disadvantages of Intermittent Production System:
i. It is expensive for high volumes since the variable cost are high for general
purpose machines.
ii. There is a large in-process inventory and there is heavy build up WIP if PPC is
not well garaged.
iii. Material handling equipment's are costly and require more space.

2.4 TYPE OF PRODUCTION SYSTEM:
A system is composed of a number of components are combined together for

the accomplishment of some pre-determine goals. Any manufacturing organization
can be termed as a production system to produce goods and services there are three
main components in this system namely inputs transformation process and output .but
these components can be divided into a number of sub components can be divided
into number of sub components operations and activities He transforming process
involves many activities and operation necessary to charge inputs into outputs these
operations and activities can be mechanical chemical inspection control material
handing operations etc output is a form, of goods and services.
Thus a combination of all activities of all activities and operations to produce

same goods and services is known as manufacturing system. The system depends on a
number of factors viz.
The above figure shows that at one end system are inputs and at the other end
output. Input and output are used by certain process or operation or activities
imparting value of input. These processes or operations or activities may be called
production system. The nature of production system differs from company to
company.
We can classify these manufacturing processes into two groups.
1. Continuous Production System.
2. Intermittent Production System.
1. Continuous Production System:
Continuous production systems are those where facilities are standardizes as to

routine and flow. Such concerns produce goods continuously for stock in anticipation
of customers demand. Such production may be classified as analytical and
synthetically production system and further be classified as.
a) Mass Production or Flow Production System:
Where large scale standardized production is done on demand basis through

standardizes process, plant layout is done in conformity with sequence of operations.

Batch production is characterized by the irregularity in the increase of work added to

the basic material. Batch production turns into flow production when the rest period
mentioned above vanishes, and si flow production can be defined as production
during which the work content of the product continually increases. The processing of
the material is continuous and progressive.
b) Process Production System:
It is an extended fro, of mass production or flow production is carried on continuously

through a predetermined course of operations. In this system the finished product of
one process is used as the raw-material for the next process till the last process large
industries like petroleum, refining, heavy chemical industries generally we this system
of production.
Under this system generally one principal raw material is transformed into several
products at different stages of production.
2.5 SCOPE OF PRODUCTION/OPERATION MANAGEMENT:
The operation or production management hast to generate customer satisfaction at an

optimum cost. These include certain long term and short term decision that are to be
taken.
The short term decisions include the following:
a) Production planning.
b) Production control.
c) Inventory control.
4) Quality control.
e) Maintenance and Replacement.
F) Cost reduction and control.
The scope of production management includes the various factors of production

function in an organization.

From both the short term and long term decision making function we have to study
the short decision in detail which are planning and control components of
production function.
A. Production planning:
Production planning is the system of specifying the production to get the desired
output in a given time at optimum cost in conformity with the specified standard of
quality and control is essential to ensure that manufacture take place in the stated in
the plan.
Production planning is pre-production activity associated with determination of

optimum production schedule, sequence of operations, and economic batch quantity
optimum job machine assignment and dispatch priories for sequencing of jobs. It has
to important sub activities of routing and scheduling.
B. Production control:
Production control is the other half of production planning and control. As profit
of planning components we have seen that production planning stands for it functions
of viz. routing scheduling. The production control involves of mainly two components
namely 'dispatching' and 'following-up'.. The dispatching function involves the actual
granting of permission proceed according to plans already laid down and which
consist of the issuance of order in terms of the priority as determined by routing and
scheduling Another part is follow-up' it is also called as expecting. Follow-up is to
oversee that things are going as per planning elements.
C. Inventory control :
Inventory is the stock and inventory control deals with the determination of
inventory levels of raw-materials, components part, spares supplies and finished good
to guarantee ready availability in least cost of capital lock up and possible losses.
D. Quality control :
This can be called as quality assurance and quality control component. Every
knows quality is an important dimensions of production and production systems that
is expected to ensure that products and sources of a unit are confirming to minimum
quality standards at a less cost. It includes aspects like such as getting the standard of

quality, inspection of purchase and control of quality during manufacturing,

inspection of finished products.
E. Maintenances and Replacement:
Maintenances and replacement activities involve the selection of optimal

maintenance policy to guarantee higher equipment availability at minimum
maintenance and repair cost. Preventive maintenance that comprises of preventive
inspection, planned lubrication, periodic cleaning and upkeep planned replacement of
parts, condition monitoring of the equipment and machines etc.
F. Cost control and Cost Reduction:
It is already pointed out that the cost of production is to be kept at minimum

through efficiency and economy measures. Control of cost is possible by executive
behavior. A costs shout be reduced to have competitive edge of competitive
advantages over others. Cost reduction as possible through research and development
activities, waste management, and time management and so on. It is cost
consciousness which breed nourishes both cost control and cost reduction.
2.6 PROCESS PLANNING:
Process planning means the complete determination of the specific

technological process steps and their sequence for the production system to produces
the product or services at the desired quantity, quality and cost.
Process planning is done while initially assuming that product or services

designs is fixed. Modifications to these initial designs and process plant are then made
while simultaneously considering both product or service design and process plans.
Process planning: Its relation with other product and operation management
activities:
Process planning brings together knowledge about product design, resources

the productive system and markets and then develops a plan for producing products or
services.
The above figure shows shot the process planning is the basic for the building, layout
of facility and section of the production equipment’s. Additionally, process planning
ultimately affects quantity control, human resources requirements, job designs and

facility capacity. In short, this important activity determines in large measure she
details of how products or services will be produced.
Process planning involves studies about product design, technological process,

production procedures, and facilities these studies result in a complete determination
of the technological process steps to be used and their sequence, the number of
personal required, their soil level and supervision requirements.
Inspection
Inspection is concerned with estimating with degree to which output confirm

with established specifications. The process by which degree of performance is
determined may range from the simplest possible comparison of the unit which a
specification by measurement with a standard instrument all the way to the life.
The inspection constitutes of the following:
a) Interpretation of the specifications
b) Measurement of the product characteristics
c) Comparison of above two
d) Judgment as to conformance
e) Disposition of materials
f) Recording or data obtained
Procedure of Inspection:
1) Determine from the purchase order that applicable sampling plan and lot size.
2) Inspect each of the sample items in accordance with the inspection specifications
noted in the purchase order.
3) If critical defects are found the entire lot is rejected.

CHAPTER III
COMPANY PROFILE
3.1 INTRODUCTION TO THE ORGANIZATION
Name Laxmi Poha, Kurmura and Rice Mill, Gadhinglaj.
Location Market Yard, Sankeshwar Road Gadhinglaj
Establishment 26 March 2004
Mobile No 9422424283
E-mail laxmiricemill@gmail.co.in
Registered office Laxmi Poha, Kurmura and Rice Mill
Nature of company Indian company
Control and Management From owner
Types of company Private Company
Laxmi Poha, Kurmura and Rice Mill, Gadhinglaj was founded by Mr.
Mallikarjun Bellad in 2004 with stating as a small-scale industries unit. It's a
manufacturing & processing industry of Rice grain. They are processing on different
rice. Laxmi Poha, Kurmura and Rice Mill, Gadhinglaj is in phase of continuous
process of expansion and modernization which enabled it tobecome the most
successful manufacturer.
3.2 BRIEF HISTORY OF ORGANIZATION
Laxmi Poha, Kurmura and Rice Mill, Gadhinglaj has been formulated by Shri.
Mallikarjun Bellad in Gadhinglaj. Tal: Gadhinglaj, Dist: Kolhapur. Firstly they come
into poha & puffed rice mill business, and then in 1990 he came into Rice Mill
Business. Now this rice mill has successfully running & creates monopoly in
Gadhinglaj, Ajara & Chandgad Tahsil by their tremendous & Continuous service
totheir Customers.
It is first concern started by Bellad Brothers in Gadhinglaj tahsil in 1990. Now along
with Mr. Mallikarjun Bellad, his son Mr. Sanket Bellad is also contributing his extra

efforts for the growth & prosperity for continuing the business successfully & he is
contributing maximum gain for this concern for increasing the profitability.
3.3 ORGANISATIONSTUCTURE
OWNER
SUPERVISOR
LABOUR
PEON

3.4 PRODUCTS


3.5 OPERATIONS MANAGEMENT OF ORGANIZATION
The main area of operation is Gadhinglaj. Manufacturing and sales is done in

Gadhinglaj tahsil. The area operations is extended to Ajara, Nesari and Chandgad.
And it has been extended in konkan area i.e Sawantwadi, Kudal and Dodamarg.
3.6 Flow Chart
MANUFACURER
TRADER
WHOLESALER
RETAILER
3.7 FUTURE PLANS OF ORGANIZATION
“To be part of globally predominant products manufacturing and excellence in

product.”
To efficiently manufacture the product and provide supply change of product

exceeding customer expectations and optimizing value through continuous quality
and innovation and provides customer good service.

CHAPTER NO. IV
DATA ANALYSIS AND INTERPRETATION
The data analysis and interpretation has classified into four parts.
PART A) CATTLE FEED
A1 PRODUCTION PROCESS OF CATTLEFEED
A2 RAW MATERIAL USED FOR CATTLE FEED
A3 PRODUCTION OF CATTLE FEED
A4 SALES OF CATTLE FEED
PART B) RICE
B1PRODUCTION PROCESS OF RICE
B2RAW MATERIAL USED FOR RICE
B3 PRODUCTION OF RICE
B4 SALES OF RICE
PART C) PUFFED RICE
C1 PRODUCTION PROCESS OFPUFFEDRICE
C2RAW MATERIALS USED FOR PUFFEDRICE
C3 PRODUCTION OF PUFFEDRICE
C4 SALES OF PUFFEDRICE

PARTD) ROASTED POHA
D1 PRODUCTION PROCESS OF ROASTED POHA
D2 RAW MATERIAL USED FOR ROASTED POHA
D3 PRODUCTION OF ROASTED POHA
D4SALES OF ROASTED POHA
PART A) CATTLE FEED PRODUCT
A1 – introduction to process
The process of manufacturing animal feed is a means whereby raw materials

of widely ranging physical, chemical and nutritional composition can be converted
into a homogenous mixture suitable for producing a desired nutritional response in the
animal to which the mixture is fed. The process is basically a physical one and
chemical changes are few. It should be remembered however that some raw materials
will have undergone extensive processing prior to inclusion into a mixed feed, for
example, extraction of oil from oilseeds by solvent or mechanical extraction, heat
treatment of soya beans or other beans to denature anti-nutritive factors, or the
production of fishmeal and meat meal. The feed manufacturing process may be
considered to be made up of several unit operations which, in almost all
circumstances, include the following:
Raw material, storage and selection.
Raw material weighing.
Raw material grinding.
Mixing of dry ingredients and addition of liquids.
Pelleting of mixed feed (optional).
Blended feed bagging, storage and dispatch.

1. Raw material, storage and selection
In order to ensure a continuous supply of raw materials at the mill, when some
may only be seasonally available on the market, and to take advantage of price
fluctuations, some form of storage will be necessary. The particular method chosen
for raw material storage will depend on the local circumstances, but in areas where
labor is cheap and plentiful and capital funds scarce, it is likely that storage in bags
will be preferable. Raw materials should arrive in good condition and in sacks which
have not been used for the storage of fertilizer, pesticides or chemicals.
Raw materials will vary from country to country and from region to region
and will have widely ranging bulk densities (weight for a given volume). These
differences in bulk density must be taken into account when determining the space
required for the storage of raw materials and finished products.
The proper storage of raw materials and of finished feeds is not only essential
to prevent physical losses, but is also an important aspect of quality control which will
be discussed in more detail later.
2. Raw material weighing
The weighing of raw materials requires great care and inaccuracies must be
kept to a minimum. It should be noted that errors in the weighing of small quantities
of raw materials often have far greater influence on the growth performance of
animals than errors in the weighing of large quantities of material, for example, the
omission of say, 25 kg of bran from a mixture requiring 400 kg of bran is of much
less significance nutritionally than the omission of 1.5 kg of vitamin pre-mix say from
the same mixture requiring only 2.5 kg of pre-mix. It may therefore be necessary to
purchase a scale to weigh small quantities, of up to 25 kg, with an accuracy ofÂ±100g
and a greater capacity scale, for example up to 500 kg with an accuracy of Â± 2.0 kg.
The use of accurate scales is of particular importance when handling expensive and/or
potent raw materials such as vitamins and medicinal additives which are added at low
inclusion rates.

3. Raw material grinding
In the sequence of unit operations involved in feed milling, raw material

grinding may occur before or after weighing. It is a process with high power
requirements which is often noisy and dusty. Because of difficulties experienced in
feeding certain raw materials (for example, barns, cottonseed cake) through a grinder,
many feed machinery manufacturers pre-blend ingredients before grinding in order
that the more easily ground materials will act as carriers or flow aids to those offering
resistance to grinding. It should also be noted that the desired fineness of grind will be
influenced by the livestock to which the feed must be fed, or by other processes
following grinding. Raw materials for poultry should be more finely ground than for
cattle or pigs and raw materials to be pelleted are usually more finely ground than the
equivalent feed as meal.
4. Mixing of dry ingredients and addition of liquids
It is the job of the mixing machinery to produce a homogenous blend of all the
raw materials desired in a formulation, such that at each feeding period each animal
receives a balanced mixture of nutrients. Not only are their requirements more
demanding, but the daily nutrient intakes of those eating small amounts of feed will
be subject to much greater variation as a result of poor mixing. Mixing often improves
feed palatability if one or more of the raw material is unpalatable to livestock.
5. Pellenting of mixed feed
Pelleting involves the compression of a mixed feed through holes in a

hardened steel ring or plate (a die) by means of hardened steel rollers. The die forms
the feed into pencil-like extrusions which are cut by knives into pellets of desired
length on leaving the die. In a ring die pelleter, the rollers or the die may be driven but
in a plate die pelleter the rollers only are driven. The die and rollers of a ring die
pelleter may operate in a horizontal or vertical plane according to machine design.
Pelleters with horizontally running dies are most commonly found in farm-scale feed
mills. The pelleting process is very energy intensive, demanding up to 50% of the
total power required for feed manufacture. The diameter of feed pellets is governed by
the diameter of the holes in the die ring but the smaller the die holes the greater effort
is required to force meal into these holes, hence the greater the power demand, that is,
the smaller the pellet, the greater the cost of manufacture.

6. Bagging
Compound feeds, whether in meal or pellet form, are usually distributed in

sacks in developing countries, although for on-farm use or for distribution to a large
livestock unit distribution could be in bins or trucks. Bags may be filled directly from
mixers or from holding bins and may be weighed on a scale balance or through an
automatic pre-set weighed and bagging unit set to weigh.
7. Quality control
Quality control is essential at all stages in the production of compound feed if

the maximum and most efficient returns are to be obtained by the feed compounder
and livestock producer. In some countries the control of feed quality is regulated by
government legislation, while in others there is no such provision. In either case,
omission of any serious attempt at quality control is false economy in the longer term
8. Other tests
In addition to the above factors, there are a number of other considerations to

be borne in mind with specific types of materials. It is important to ensure that
processed materials, particularly those of animal origin such as fish, meat and bone
meal, do not contain any pathogenic bacteria which could cause diseases in animals to
which they are fed. The most common pathogenic organism encountered is
salmonella, and it is important that consignments, particularly from new suppliers of
processed materials, be tested for this organism.
9. Finished feeds
If the raw materials and processing conditions are of the correct standard, then
the product should also be of the correct standard. However, variations and errors can
arise in the weighing or accidental omission of an individual raw material. The
omission of a small quantity of vitamin supplement may have a marked adverse effect
on the health and growth rate of animals receiving the feed. For this reason,
considerable care must be exercised in ensuring that the specified amounts of all raw
materials are weighed out for each batch, and an appropriate system for checking this
should be devised. It is important that representative samples of batches be taken for
check analyses to monitor the composition of the finished feeds. If results show
deviations from the required composition, the reasons for this must be sought and

rectified. In some countries there may be statutory requirements for the composition
of feed offered for sale.

Table No. 4.1
Raw Material used for Cattle Feeds as per Year
(In kg)
Year Corn Rice Rice Puff Rice Wheat Total

Husk bran Wastage
2016-17 9200 10120 7800 9900 7970 44990
2017-18 10190 11200 8320 10920 9320 49950
2018-19 11200 12320 9830 12140 10840 56330
2019-20 6000 7000 5000 7000 5000 30000
2020-21 8000 9700 6900 8700 6800 40100
Figure No 4.1
Interpretation
Above table and figure shows that raw material used for Cattle Feeds i.e.
Corn, Rice husk, Rice Bran, Puff Rice wastage and Wheat are used as raw material
for production of rice. In 2016-17 totally 44990 kg of raw material was used. In 2017-
18 totally 49950 kg of raw material was used. In 2018-19 totally 56330 kg raw
material was used. In 2019-20 totally 30000 raw material was used here we seen that
the raw material was decreased compare to previous years. In 2020-21 totally 40100
kg raw material was used.

Table No. 4.2
Production of Cattle Feeds as per Year in Particular Quality
(in kg)
Year Kavya Brand Dudhsagar Brand Total

2016-17 23990 21000 44990
2017-18 26500 23450 49950
2018-19 29200 27130 56330
2019-20 16000 14000 30000
2020-21 21000 19100 40100
Figure No 2
Interpretation
Above table and figure shows that production of Cattle Feeds. In 2016-17 the
production of kavya brand was 23990 kg and production of dhudhsagar brand was
21000kg in 2017-18 the production of kavya brand was 26500 kg and Dudhsagar
brand was 23450 kg. In 2018-19 the production of kavya brand was 29200 kg and the
production of dhudhsagar brand was 27130 kg. In 2019-20 the production of kavya
brand was 16000 kg and the production of dhudhsagar brand was 14000 kg. In 2020-
21 the production of kavya brand was 21000 kg and Dudhsagar brand was 19100 kg.

Table No. 4.3
Sales of Cattle Feeds as Per Year
(In kg)
Year Kavya Brand Dudhsagar Brand Total

2016-17 23800 20200 44000
2017-18 26500 23450 49950
2018-19 29000 27000 56000
2019-20 16000 14000 30000
2020-21 21000 19000 40000
Figure No 4.3
Interpretation
Above table and figure shows that sales of Cattle Feeds. In 2016-17,the sales
of kavya brand were 23800 kg and the sales of duchsagar brand were 20200 kg. In
2017-18, the sales of kavya brand were 26500 kg and the sales of dudhsagar brand
were 23450 kg. In 2018-19, the sales of kavya brand were 27000 kg and the sales of
dudhsagar brand were 56000 kg. In 2019-20, the sales of kavya brand were 14000kg
and the sales of dudhsagar brand were 30000kg. In 2020-21 the sales of kavya brand
were 19000 kg and the sales of dudhsagar brand were 40000.

PART B) RICE
B. 1 – RICE PROCESS
Rice Processing Steps
1. Pre-cleaning.
2. De-husking.
3. Paddy Separating.
4. Milling.
5. Grading.
1. Pre-cleaning
Pre-cleaning process consists of two procedures
a) Cleaning -
Paddy cleaner is the most essential equipment in a rice mill, as it separates all
impurities.
b) De-stoning -
This procedure includes separating of dust, straw, sand, clay and heavy
particles of even and uneven sizes from paddy.
2. De-husking
Rice de-husking process of removing the husk and bran from the paddy rice
and producing head white rice grains that are sufficiently milled, free from impurities
and contains minimum number of broken rice
3. Paddy Separating
Rice separator separates the un-husked paddy from the brown rice. This
procedure is a simplest form and this is known as easy process.
4. Milling -
The rice milling is the process that helps in removal of hulls and bran's from
paddy pains to produce polished rice. White rice is the result of further milling by

machine at rubs the grains together under pressure. This abrasion removes the bran
layers. nealing "white" or "polished" rice. Rice milling machine is used.
5. Rice Grading -
a) Immature grains are separated.
b) A more precise adjustment of huller is possible, which minimizes breakages.
c) Independent milling of graded lots is possible.
6. Weighing and bagging -
Preparing the milled rice for transport to the customer.
Furthermore as the increasing cost of conventional fuel and environment

issues, people have turned to clean fuel and energy for living and production, some
waste material such as, crop stalk and waste material such as, crop stalk and straw,
rice husk, peanut shell, leaves, sawdust, etc. can be pressed into solid briquettes by
using Biomass briquette, which reduce environmental pollution and recycling for crop
wastes.

Table No. 4.4
Raw Material Used For Rice Productions as Per Year in Particular Quality.
(in kg)
Year Daftari Ratna Indrayani Sonam Jaya Shubhang Basmati Paraboil Total
-giri i
2016-17 6500 8500 9000 4000 3200 2500 4800 2500 41000
2017-18 7200 9000 9500 4500 3500 3000 5200 2800 44700
2018-19 7500 9500 10000 5200 3800 3200 5800 3400 48400
2019-20 5000 7000 8500 3000 2500 2000 4000 2000 34000
2020-21 6000 8000 9000 3500 3000 2200 4500 2300 38500
Figure No 4.4
Interpretation
Above table and figure shows that raw material used for Rice. In 2016-17, raw
material is 41000 kg and it was increased in 2017-18 and went up to 44700kg. It was
48400 kg in the year 2018-19, where it was 34000 kg in the year 2019-20 raw
material used. In 2020-21, total 38500 kg raw material was used.

Table No. 4.5
Rice Production as per Year in particular Quality
(in kg)
Year Daftari Ratna- Indrayani Sonam Jaya Shubhangi Basmati Paraboil Total
giri
2016-17 4225 5525 5800 2600 2080 1625 3120 1625 26650
2017-18 4680 5850 6175 2925 2275 2000 3380 1820 29105
2018-19 4875 6175 6500 3380 2470 2100 3770 2210 31480
2019-20 3250 4600 5600 2000 1600 1350 2650 1300 22350
2020-21 3900 5200 5850 2300 2000 1430 3000 1480 25160
Figure No 4.5
Interpretation
Above table and figure shows that the rice production. Rice production is
26650 kg in 2016-17, were it was 29105 kg in 2017-18.It was 31480 kg in the year
2018-19 and it was 22350 kg production has decreased in 2019-20, were in the year
2020-21 it was 25160 kg.

Table No. 4.6
Sales of Rice as per Year
Year Daftari Ratna- Indra- Sonam Jaya Shubhangi Basmati Paraboi Total
giri yani l
2016-17 4100 5575 5900 2625 2150 1700 3100 1650 26800
2017-18 4800 5800 6000 2900 2300 1980 3450 1800 29030
2018-19 4880 6200 6300 3400 2470 2130 3720 2250 31350
2019-20 3200 4500 5300 1950 1550 1250 2550 1260 21560
2020-21 3950 5250 6100 2325 1950 1490 3050 1460 25575
Figure No 4.6
Interpretation
From the above table and figure, the sales of rice in 2016-17 were 26800 kg and the
sale for 2017-18 was 29030 kg. It was 31350 kg in 2018-19 and it was 21560 kg in
the year 2019-20, in the year 2020-21 the sale was 25575 kg.

PART C) PUFFED RICE
C.1 Process:
Puffed Rice are made in various Process
Process I
Sun dried paddy is filled in mud jars and is moistened with hot water.
2 after 2-3 min. the water is decanted and the jars are kept in an inverted position
for8-10 hours.
3. Next the paddy is exposed to the sun for a short time and then parched in hot sands
in the preparation of parched rice.
4 Puffed rice is prepared by throwing pretreated paddy into sand heated to a high
temperature in an iron pan
5 During parching the grain swell and burst into a soft white product. The parched
grains are sieved to remove sand and winnowed to separate the busk
Process II
This popular ready-to-eat snack product is obtained by puffing milled parboiled rice
in the traditional process rice is gently heated on the furnace without sand to reduce
the moisture content slightly.
It is then mixed with salt solution and again roasted on furnace in small batches with
sand on a strong fire for a few seconds to produce the expanded rice. Rice expands
about 8 times retaining the grain shape and is highly porous and crisp

Table No. 4.7
Raw Material used for Puffed Rice as per Year
(in kg)
Year Raw Material of

Hawala Rice
2016-17 120000
2017-18 140000
2018-19 160000
2019-20 80000
2020-21 100000
Figure No 4.7
Interpretation
Above table and figure shows that Raw Material Used for Production of
Puffed Rice. In 2016-17 120000 kg raw material was used. In 2017-18 140000 kg raw
material was used. In 2018-19160000 kg raw material was used. In 2019-2080000 and
it 100000 kg raw material was used in 2020-21.

Table No. 4.8
Production of Puffed Rice as per Year
(in kg)
Year Production of Hawala

Puffed Rice
2016-17 84000
2017-18 98000
2018-19 112000
2019-20 56000
2020-21 65000
Figure No 4.8
Interpretation
Above table and figure shows that Production of Puffed Rice. In 2016-17,84000 kg
puffed rice was produced. In 2017-18, 98000 kg puffed rice was produced. In 2018-
19, 112000 kg puffed rice was produced. In 2019-20, 56000 kg puffed rice was
produced. In 2020-21, 65000 kg puffed rice was produced.

Table No 4.9
Sales of Puffed Rice as per Year
(in kg)
Year Sales of Hawala

Puffed Rice
2016-17 83900
2017-18 9800
2018-19 112000
2019-20 56000
2020-21 64900
Figure No 4.9
Interpretation
Above table and figure shows that sales of Puffed Rice. In 2016-17, the sales
of puffed rice was 83900 kg. In 2017-18 the sales of puffed rice was 98000 kg. In
2018-19, the sales of puffed rice is 112000 kg. In 2019-20, the sales of puffed rice is
56000 kg. In 2020-21, the sales of puffed rice is 65000 kg.
PART D) ROASTED POHA

D.1 - Process:
1. Raw Poha get processed in the roster for that it required things are:
2. The wood is required for the flame which is required to roast the raw poha in
roaster it needs high flame.
3. The Poha will be roasted in sand which will be in the roaster the flame will
generate the heat and in that heat the Poha will be roasted. The sand will be
bringing from Alibaug. And that sand contains salt
4. Roasted Poha is mostly used in Diwali, Ganesh chaturthi, and in many more
festival and it is prepared as chivda.
Table No. 4.10

Row Material used for Roasted Poha as per Year
(in kg)
Raw Material
Year
Raw Rice Flakes
2016-17 15000
2017-18 20000
2018-19 25000
2019-20 10000
2020-21 7000
Figure No 4.10
Interpretation
Above table and figure shows that Raw Material Used for Production of
Roasted Poha. In 2016-17 15000 kg raw rice flakes was used. In 2017-1820000 kg
raw rice flakes was used. In 2018-1925000 kg raw rice flakes was used. In 2019-
2010000 kg raw rice flakes was used. In 2020-21 7000 kg raw rice flakes was used
Table No. 4.11

Production of Rosted Poha
(In kg)
Year Production
2016-17 15000
2017-18 19500
2018-19 25000
2019-20 6500
2020-21 9000
Figure No 4.11
Interpretation
Above table and figure shows that production of roasted poha. In 2016-17,
15000 Kg of roasted poha was produced. In 2017-18, 19500 Kg of roasted poha was
produced. In 2018-1925000 Kg of roasted poha was produced. In 2019-20 6500 Kgof
roasted poha was produced. In 2020-21 9000 Kg of roasted poha was produced.
Table No. 4.12

Sales of Rosted Poha as per Year in Particular Area
(in kg)
Year Ajara Chandagad Gadhinglaj Nesari Total

2016-17 4000 3500 4500 3000 15000
2017-18 5500 5000 6000 3000 19500
2018-19 6000 6000 8000 5000 25000
2019-20 1500 1500 2500 1000 6500
2020-21 2000 2500 3000 1500 9000
Figure No 4.12

CHAPTER V
FINDING AND OBSERVATION
1. It has been found that the raw material used for cattle feeds is increased year
by year and 2019-20 and 2020-21 is using of raw material was less.
2. It has been found that production of cattle feeds in increasing continuously
from 2016-17 to 2018-19.
3. It has been observed that the sale of cattle feeds has increased every year. Its
to be observed that there is maximum sale of kavya brand CA compare to
Dudhsagar brand. But there is a good sale of cattle feeds.
4. It has been observed that there is increased in raw material uses for Rice
production.. Ratnagiri and Indrayani rice grains are used as much as a raw
material mostly compare to others
5. It has been observed that the level of production also increased year to year.
Indrayani and Ratnagiri rice grains are mostly produced and there is also
increasing brand in Daftari rice production too.
6. It has been observed that the more sale of Ratnagiri and Indrayani rice.
7. It has been observed that the raw material used for puffed rice is increased in
2018-19 and decrease in 2019-20
8. It has been observed that the production of puffed rice is also increased in
2018-19 compare to another years.
9. It has been observed that there is increasing trend in sale of puffed rice there is
good growth in a sale of puffed rice from 2016-17 to 2019-20
10. It has been observed that there is tremendous decreased trend of raw material
used for roasted poha it is less than triple compare to 2016-17.
11. It has been observed that the production of roasted poha is 15000kg in 2016-
17 and it increased in 2018-19 it observed that there was an increasing trend.
12. It has been observed that the sale of roosted poha is also increasing with
growth rate there is on growth trend in the sale.

CHAPTER VI
SUGGESTION AND CONCLUSION
SUGGESTIONS
1. It is to be suggesting that there focus a sale of Dudhsagar brand and try to raise
Dudhsagar brand for cattle feeds.
2. It is to be suggesting that there is need to produce a Basmati brand and Sonam

brand too
3. It is to be suggesting that there is need to increase in the sale of Basmati and Sonam
rice also
4. It is to be suggesting that there is need to control in stoppage of wastage of raw

material for puffed rice. There is need to do a wastage control and control of abnormal
loss of raw material.
5. It is to be suggesting that there is need to focus to Nesari area for selling of roasted
poha. The organization also needs to concentrate Chandgad area for sale of roasted
poha.
6. It has been found that the sale of roasted poha in Nesari report is comparatively
lower than other so, I would like to suggest that organization keep focusing on nesari
area in sales of roasted poha context.

CONCLUSION
` It is to be concluding that, there is a proper process of production of finished

goods by use of raw material. There is a proper sales management for increasing a
sale. The companies have a good policy for raw material collection management.
Lastly, it is to be concluded that the company is having a proper production and
planning control.

BIBLIOGRAPHY
Article
European journal of operation research 1993, production planning and control
Books:
1. Production and Operation Management, S.A. Chunawalla, Himalaya Publishing

House.
2. Production Management, S. Chand, Publishing House.
3. Business Statistics, Prof. Neerja Srivastava, Thakur Publishers, Pune.
Websites
www.laxmiricemill.com - 12/04/2022
www.google.com - 14/04/2022

A Study of Production Planning and Control

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A Study of Production Planning and Control

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Shivaji University, Kolhapur Production Planning & Control

Production planning and control involves generally the organization and

Production planning and control is the organization and planning of the

Production is any activity directed to the satisfaction of other people’s wants

Planning is the fundamental management function, which involves deciding

Dr. Ghali College, Gadhinglaj Page 1

Controlling is one of the managerial functions and it is an important element of the

1.2 MANAGEMENT PROBLEM

1.3 OBJECTIVES OF THE STUDY

1] To study the concept of production and control.

3] To understand the production planning and production analysis of products of the

4] To give necessary suggestion, if it requires.

1.4 SCOPE OF STUDY

1.5 IMPORTANCE OF THE STUDY

Dr. Ghali College, Gadhinglaj Page 2

1.6 RESEARCH METHODOLOGY:

Data Analysis Instrument

1.7 LIMITATIONS OF STUDY

1 The study is limited to 30 days.

1.8 REVIEW OF LITERATURE

1. European journal of operational research 1993 production planning and control is

Dr. Ghali College, Gadhinglaj Page 3

Production in the other world is a transformation system where inputs, are

In short production process is backbone of all manufacturing activity and it is

Dr. Ghali College, Gadhinglaj Page 4

MEANNG AND DEFINITION OF ‘PRODUCT PROCESS'

The word production management arrived first with the emergence if

Production Process is the sequence of operation that transforms material given

C. Type of production system

D. Production Planning and Control

The meaning of the term "Production Management" is certified in the

1) "Production management" is the process of planning, organizing, directing and

Dr. Ghali College, Gadhinglaj Page 5

3) According to A.H. Harding:

4) According to E.S. Buffa:

"Production management deals with decision-making related to production process so

a) It is a decision-making managerial function.

c) The production or output should be according to specifications, in the specified

2.2 OBJECTIVE OF PRODUCTION PROCESS:

The production objectives are majority divided into two categories.

The primary responsibility of the manufacturing activity is to produce the product or

1) Pre established cost.

2) According to the specified quality and within the stipulates time.

Thus the ultimate objectives can be sub-classified as under

Dr. Ghali College, Gadhinglaj Page 6

1. Machine and Equipment:

It includes the acquisition and utilization of machinery and equipment.

Dr. Ghali College, Gadhinglaj Page 7

2.3 ADVANTAGES OF CONTINUOUS PRODUCTION SYSTEM:

i. It has low unit cost per unit production.

iii. The managerial control simpler.

Disadvantages of continuous production system:

Through cost effective is suffers from following disadvantages.

i. It is difficult to adopt it to a different product line it is also difficult to change the

ii. Breakdown results in stoppage of line.

The production system can be classified as:

a) Job shop production :

Dr. Ghali College, Gadhinglaj Page 8

Enterprises producing capital goods such as heavy, special purpose machinery

Under this system production is done in groups or batches on medium scale. As

Advantages of Intermittent Production System:

Following are the advantages of Intermittent Production System:

i. It is a trade of between flexibility and efficiency.