Академический Документы
Профессиональный Документы
Культура Документы
Product design and development: This deals with the issues of converting market feedback on the
requirements pertaining to the type of product to be produced into specifications and drawings that help in
production.
Production process selection: This helps in evaluating different process options possible to produce the
type of product in terms of volume and variety and other factors to select the best-suited process.
Planning facility location: This deals with evaluation of different possible locations for production and
selecting the most suitable one that meets the organizational objectives of production in the required
quantities at the minimal costs.
Planning facility layout: This refers to studying various options in terms of plant and machinery layout
that enables the smooth flow of materials for smooth production.
Capacity planning: This deals with the issues pertaining to planning the capacity for the plant that
enables cost-competitive production event with certain degree of fluctuations in the required volumes.
Production planning: This helps effectively plan the production to meet the required quantities of
products within the scheduled time.
Organizing
Work study: Also known as time and motion study, it aims at improving the cycle time required for
producing a product.
Materials management: This aims at establishing sources for the required materials in terms of input
materials or consumables at the right time so that no delays in production occur.
Purchasing management: This is responsible for making the input material available in time, at the
right price and in the right quantity and quality.
Controlling:
Stores management: This refers to managing the stores for input materials, consumables and finished
stocks while avoiding overstocking of materials. Stores are also accountable for recording the stock and
consumption of these materials.
Value analysis: The process of obtaining the best possible combination between cost and required
functional specifications of a product by assigning a value to every operation of the production process
and identifying the function of the product. This helps in enhancing the value of the product.
Quality control: This is responsible for monitoring the quality requirements of the product so that no
defective parts are passed on to the consumers. For this, systems associated with the processes are
assessed by the management of an organization in order to improve them so that no defective parts are
produced.
Maintenance management: This is responsible for ensuring the continuous production in terms of
machinery and other required infrastructure so that no breakdowns occur to hamper the production flow.
It also includes proactive preventive maintenance to maintain the health and performance of the machines
in peak condition.
Inventory management: This is responsible for maintaining minimum inventory of all critical
materials and ensuring that there is no overstocking or stock-out.
2 Discuss the any five main functions of production planning and control.
ANSWER:
The main activities encompassing Production Planning and Control (PPC) are as follows:
(i) Order preparation: The work of PPC begins once an order is received from the sales department.
This order is then converted into a work order or shop order and sent to various departments
concerned, action planning.
(ii) Materials planning: On receiving the order PPC decides the raw materials required for
manufacturing, considering the capacity of various production shops, the bill of materials, inventory on
hand, and lead time for procurement.
(iii) Routing (or process planning): Routing means determination of the sequence of operations for
manufacturing a product or service. This path is determined in advance and forms the basis for most of
the scheduling and dispatching functions. According to Kimball and Kimball, Routing is the selection of
path or route over which each piece is to travel in being transformed from raw material into finished
product. Routing includes the following activities:
Deciding the volume of production
Selecting the men, machines and materials to be used in its production
Deciding the type, number, and sequence of production operations
Deciding the place where production is to be carried out
When routing or process planning is being done, a route sheet is prepared.
(iv)Estimating: This involves establishing the operation time for every process; this also leads to fixation
of performance standards for both men and machines.
(v) Scheduling: According to Spriegal and Lanburgh, Scheduling involves establishing the amount of
work to be done and the time when each element of work will start or order of the work. Thus,
scheduling includes the following activities:
Determination of quality and rate of output of the plant or department
Allocation of time for each operation The scheduling function begins when the following information is
furnished:
Date of delivery specified by the customers order
Time required for assembly and subassembly process
Time to be taken in the production of component parts
Time required to make purchases
Time required for moving the materials from one station to the other, inspection, etc.
Priority of orders
Necessary provisions for unforeseen contingencies such as power breakdown, strike and lockout, absence
of workers or rush of orders of extreme importance, etc., are usually made when the schedule is prepared.
(vi) Loading: This involves allocating jobs to machines as per the capacity of machines and priority of
jobs to be done, so that the machinery is utilized to the maximum possible extent. It includes the
following activities: Preparation of machine loads
Fixing of actual dates of various operations/sequence of operations to be performed on the jobs
Coordination with the sales department to confirm delivery dates and keeping them informed about the
status of the schedules
(vii) Dispatching: Dispatching means preparation and distribution of work orders and manufacturing
instructions to the concerned departments in accordance with the details worked out under routing and
scheduling functions. The work order received by the various departments is an authority for them to start
the work according to that schedule.
(viii) Progressing: This involves controlling the process of production, collecting data from various
manufacturing shops, recording the progress of work and comparing progress against the plan.
(ix) Expediting and follow-up: Follow-up means to see whether the work is being carried out according
to the plan and orders and instructions issued. It ascertains that the materials, tools and equipment are
supplied at the job at the right time and to the right person or job. Follow-up is the means by which the
progress and execution of the plan is evaluated from time to time and divergence from the plan is noted.
The reasons for such divergence are then found out and efforts are made to eliminate them from the plan.
(x) Inspection: Inspection means comparing the actual with the written or expected specifications and
assessing whether they have been met. Inspection can be process inspection or product inspection, in
which the process or the product is inspected respectively.
(xi) Cost control: Production planning and control is responsible for cost control and cost reduction by
reducing or eliminating wastes, value analysis, etc.
(xii) Miscellaneous functions: There are certain miscellaneous functions such as building cost estimates
for products, fixing standards with the help of industrial engineering department, capacity planning,
making or buying decisions, making specifications of raw materials, process improvement, etc., have to
be performed.
4What are the various types of Projects , list their advantages and Disadvantages?
ANSWER:
A project requires the coordinated functioning of several units of an organization such as, finance, HRD,
information system, etc. For every project, a separate team is formed consisting of project manager and a
project leader.
(i) On the basis of composition
Projects can be classified on the basis of composition mainly into three types:
Pure project
Functional project
Matrix project
(i) Pure project is one in which a self-contained team works full-time on the project. A team typically
consists of a project leader and team members that report to him and only him.
Advantages
The project manager has complete authority over the project.
Team members need not worry about multi reporting with a functional area manager and they have a
single reporting.
Short communication lines lead to quick decisions.
Pride, motivation, and commitment of the team are high.
Disadvantages
Resource duplication occurs due to non-sharing of equipment and people across projects.
Ignorance of organizational goals and policies happens due to removal of, team members both
physically and psychologically from the head office.
Project close-up is mostly delayed due to the anxiety of team members having no functional home area
and life-after-project.
It is doomed to failure unless the project manager has strong negotiating skills.
(f) Scheduling the frequency of lubrication: The frequency of lubricating a machine or its parts depends
upon their functions and machine requirements. While some moving parts such as tool slides and guide
ways are oiled two to three times a day, some other parts are lubricated once a month or once in six
months.
(g) Deciding the amount of lubrication required: To ensure proper lubrication, care should be taken
that the lubricating agent or oil is used in oil will make a machine abrasive and damage the moving parts.
Over lubrication is also bad since it can cause overflowing especially in oil tanks, etc.
(h) Selecting the right lubricant: The right quality of lubricant is essential for good lubrication and the
long life of a machine. The right quality of lubricant is often mentioned in the instruction manual
provided by the manufacturer.