Introduction

Production Planning implies formulation, coordination and determination of activities in a manufacturing system necessary for the accomplishment of desired objectives where as production control is the process of maintaining a balance between various activities evolved during production planning providing most effective and efficient utilisation of resources.

Scope of PPC

Liaison with purchase department for efficient and effective procurement of inputs. Liaison with marketing department to determine the nature and magnitude of output. To plan the layout of the operations indicating in detail the places/points in the system where various production activities/operations are to be performed. Establishment of time schedules for levels of production by setting up necessary standards. Ensuring continuous inspection over the quality of goods manufactured. Instituting necessary controls to complete the work according to schedule.

Levels of Production Planning

Factory Planning Process Planning Operation Planning

Planning and Manufacturing systems

Production Planning depends on the nature of manufacturing systems. Manufacturing Systems The manufacturing system is viewed as an interdependent group of sub-systems, each related to its successor , each performing a different function though yet united with other for achievement of the overall system objectives. Intermittent System Continuous System

Manufacturing Systems
Intermittent Job Production Batch Production Continuous Mass Production Process Production

Intermittent System

Intermittent production systems are those where the production facilities are flexible enough to handle a wide variety of products and sizes. The goods are manufactured specially to fulfill orders made by customers.

Characteristics of Intermittent System

Most products are produced in small quantities Machines and equipments are laid out by process Workloads are generally unbalanced Highly skilled labours are required In-process inventory is large Flexible to suit production varieties

Job Production

Whole project is taken as a single operation. Work is to be completed on each product before processing the next item. Versatile and skilled labour is needed. High capital investment. High unit cost of production. Control operations are relatively simple.

Batch Production

In this system a batch is not produced to next operation until the work on the previous operation is complete for the whole batch. Comparatively low investment. Organisation & Planning is more complicated. Items are produced to definite customer orders and not for stock.

Features of an Intermittent System

Demand can be discontinuous. Elaborate sequencing and scheduling is required. Needs high investment. Can adjust to new situation and specification. Items are manufactured according to order.

Continuous System

In this the items are produced for the stocks and not for specific orders. The control mechanism is not elaborate and complex. Standardized production process is employed. Continuous system is divided into two types of production namely: Mass and Process production

Mass Production

Items produced in large quantities and much emphasis is not given to consumer orders. Uniform and uninterrupted flow of material is maintained through predetermined sequence of operations. The system can produce only one type of product at one time.

Process Production

More stress is laid on automation in production process. The volume of production is very high. Used for manufacturing those items whose demand is continuous and high.

Features of continuous type of Manufacturing Systems

There must be continuity of demand. The product must be standardised. All operational stages in the process must be balanced. Work must conform to quality standards. Advantages High Accuracy Work in progress is at a minimum Storage at different stages of operation not necessary Control process simple. Material requirements can be accurately planned.

Difference between Intermittent and Continuous manufacturing systems