40 Questions
What is the primary objective of creating a manufacturing organization?
To make products
What is the relationship between planning and control?
They are interdependent but separate functions
What is the primary function of PPC in manufacturing?
To look after manufacturing activities
What is the purpose of setting standards in planning?
To assess performance
What is the relationship between PPC and other departments in an industrial organization?
PPC intervenes into many departments
What is the main criterion for analyzing the feasibility of a project?
Rate of return on invested capital
What is a key characteristic of planning?
It is biased towards the chosen objective
What is the primary focus of aggregate planning?
Determining the production rate to meet anticipated output requirements
What is the main difference between production planning and scheduling?
Production planning is focused on the future, while scheduling is focused on the present
What is the primary purpose of scheduling?
To provide detailed plans for utilizing facilities to achieve immediate product objectives
What is the primary objective of facility layout in production system design?
To optimize the arrangements of '4 m's' and supporting services
What is the purpose of conducting a method study in operation planning?
To eliminate the wastage due to ill directed and inefficient motions
What is the main consideration while deciding the capacity of a project?
All of the above
What is the purpose of preparing a 'bill of materials'?
To prepare the detailed specifications of raw materials and finished product
What is the main purpose of budgeting in a production system?
To forecast and preplan for a particular future period
What is the primary objective of production control?
To produce products of right quality, in right quantity at the right time
What is the main focus of the preplanning stage in production?
Developing and designing a work or production
What is the primary role of the design department in PPC?
To anticipate and improve product design
What is the main purpose of planning in production?
To anticipate possible difficulties and decide in advance
What is the main goal of project planning?
To work out every detail in anticipation
What is the primary purpose of machine loading in production planning?
To ensure smooth workflow and efficient machine utilization
What is the main difference between planning and scheduling?
Planning is a broad plan, while scheduling is a detailed plan
What is the purpose of decision rules in scheduling?
To provide guidelines for scheduling decisions
What is an example of a decision rule in scheduling?
Scheduling jobs in the order they are received
What is a key characteristic of a schedule in production planning?
It is a detailed plan that outlines specific activities
What is the primary purpose of theMeasurement step in the control cycle?
To measure the variations in physical properties
What is the outcome of the Capability Studies in the control cycle?
Accurate projection of what can be done
What is the main purpose of the Evaluation step in the control cycle?
To compare the operation's performance with plans and objectives
What is the key characteristic of feedback in the control cycle?
It provides information about the operation's performance
What is necessary for the successful implementation of a plan in production control?
Both feedback and flexibility
What is the primary purpose of inventory control in production?
To provide warning of deviations and permit corrective action
What is a key characteristic of a production system?
It combines materials, labor, and capital resources in an organized way
What are the three main factors that determine the place of production planning and control in an organization?
Type of production, size of the plant, and type of industry
What is one of the main objectives of production planning?
To determine capacity of all manufacturing departments
What is true about the principles of control?
They are the same for production control, quality control, and budgetary control
What is the primary goal of manufacturing in terms of quantity, quality, and time?
Manufacturing the required quantity of product of required quality, at the required time by the best and cheapest method
What is the purpose of the 'Methods' function in PPC?
To analyze and select the best method of manufacturing according to the given circumstances
What is routing in the context of PPC?
The specification of the flow of sequence of operation and processes to be followed in producing a particular manufacturing lot
What is the purpose of estimating in PPC?
To work out the operation time when production orders and detailed operation sheets are available
What is a factor that affects the routing procedure?
Availability of plant equipment and its component parts
Study Notes
Understanding Production Planning and Control
Importance of PPC
- PPC (Production Planning and Control) is essential for the effective operation of a manufacturing organization
- It involves planning, organizing, and controlling the production process to achieve the organization's objectives
Functions of PPC
- Planning: deciding what, how, and when to produce
- Routing: determining the sequence of operations and the path of material flow
- Dispatching: releasing orders and schedules to the production floor
- Controlling: monitoring and correcting the production process to ensure it meets the plan
Pre-Planning
- Identifying what to produce and how to produce it
- Involves forecasting, product design, jig and tool design, machine selection, and estimating
Planning
- Deciding where and when to produce
- Includes sequencing of operations, scheduling, material planning, and machine loading
Control
- Ensuring the planned action is carried out
- Involves measurement of actual results, comparison with planned results, and feeding back information to planning stage
Project Planning
Steps in Project Planning
- Market survey
- Project capacity
- Selection of site
- Plant layout
- Design and drawing
- Material requirement
- Operation planning
- Machine loading
- Sub-contract consideration
- Equipment requirement
- Organizational layout and staff requirement
- Material handling
- Budgeting
- Cost calculation
- Procurement of finance
- Critical report on feasibility
Planning and Scheduling
Types of Production Planning
- Project planning
- Lot or batch planning
- Progressive or continuous planning
Scheduling
- Providing detailed plans for utilizing facilities to achieve immediate product objectives
- Starts with the desired end results and provides a blueprint for accomplishing tasks
Inventory Control
- Related aspect of production control
- Involves managing inventory levels to meet production plans and customer delivery requirements
Production
Definition
- The process of creating goods and services
Production System
- Combines materials, labor, and capital resources to produce goods or services
- Involves inputs from other subsystems, such as service inputs and control inputs
Objectives of Production Planning
- Determine capacity of manufacturing departments and plan production activities
- Translate sales orders into production orders
- Ensure availability of materials and resources
- Coordinate departmental activities
- Promote fuller utilization of plants
- Assist labor in earning more
- Train staff in effective performance of duties
Control
Principles of Control
- Action, feedback, evaluation, and adjustment
Steps in Control Cycle
-
Operation
-
Measurement
-
Capability studies
-
Objectives
-
Evaluation
-
Adjustment### Feedback and Flexibility
-
Feedback is information received after the performance of an action that is used as the basis for future performance
-
Feedback is vital for control and improvement
-
Flexibility is necessary for successful plant implementation, which implies the establishment of details, benchmarks, and measures of progress
-
Feedback and flexibility are key to successful implementation and improvement
Functions of PPC
- The goal of PPC is to obtain the highest efficiency in production by manufacturing the required quantity of product at the required time by the best and cheapest method
- The main functions of PPC are:
- Coordinating all manufacturing activities
- Ensuring materials are available on time
- Analyzing and selecting the best method of manufacture
- Relating methods to available production facilities and determining equipment replacement policy
- Determining the sequence of operations and the division of products into assemblies and sub-assemblies
- Designing economy of jigs and fixtures
Routing
- Routing specifies the flow of sequence of operations and processes to be followed in producing a particular manufacturing lot
- Routing determines what work will be done on the product, where, and how it will be done
- Routing estimates the operations, their path, sequence, and class of machines and personnel required
- Routing involves determining what to make and what to purchase based on relative cost, technical considerations, purchasing policies, and availability of equipment and personnel
Estimating, Loading, and Scheduling
- Estimating involves working out operation times based on production orders and detailed operation sheets
- Loading involves allocating machines according to their capabilities and performance
- Scheduling involves determining what, when, and where specific resources will be employed to produce specified output
- Scheduling can be simple or complex, and decision rules are necessary to tie the scheduling function with overall company goals and objectives
- Examples of decision rules for scheduling include:
- Scheduling the longest jobs first
- Scheduling jobs in the order they are received
- Scheduling the job with the earliest delivery dates first
- Scheduling jobs on a random basis
- Scheduling first those jobs with the greatest idle capacity
- Scheduling all jobs first which requires operation in a specific department
- Scheduling customer orders based on priority
This quiz introduces the basics of Production Planning and Control (PPC) and its importance in running an organization effectively and efficiently. Understand the methods, plans, and techniques essential for industrial operations.
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