Rajalakshmi Engineering College

Department of Mechanical Engineering

ME 1015 – Production Planning and Control

Notes on Lesson

Unit -1

• Objectives and benefits of planning and control: Effective equipment

utilization and resources. Improve production rate and optimum loading to
machines. Control work in process inventory and help to achieve production
target.

• Functions of production planning and control: Material, method, machine and

equipment, routing, loading and scheduling, estimating, expediting, dispatching,
inspection and evaluation.

• Types of production system: Comparative study of the production system which

comprises of Job, Batch, Mass and continuous production based on variety of
products, volume of production, machines used, type of layout, required skill
level with its merits and demerits.

• Product Design and Development: Need for design. Characteristics for a good
product design like repairability, maintainability, reliability, modular design,
durability, miniaturization etc. Phases in product development which includes
concept development, product planning, product/ process engineering, pilot
production.

• Factors influencing product design: Various factors which influence product

design like marketing aspect, functional aspect, operational aspect, aesthetic
aspect, economic aspect, production aspect, etc.
 • Standardization: Definition, Aim, classification of standardization like, Basic
standardization, dimensional, material, equipment, process, quantity, etc. Benefits
and limitation of standardization.

• Simplification: Objectives and benefits of simplification, Effects with respect to

% of products with respect to % of sales income.

• Specialization: Process by which concentrate on the manufacture of limited

number of products or type of products.

• Break Even analysis: Aims, assumptions, determination of break even point by

algebraic method, graphical method. Problems in Break even point based on
various parameters such as quantity, cost and other variables.

• Economics of new design: Careful analysis of the economics of the preferred

project to be undertaken by introducing a new model taking into consideration the
profits of organization, to avoid declining in sale of the existing model.

Unit -2

• Method study: Objectives and advantages of method study, factors facilitating

method study, Method study procedure which include select record using process
charts and diagrams. Examine using 5 W, 1 H, Develop by generating
alternatives, Install and maintain the new system.

• Recording of process: Outline process chart, operation process chart, flow

process chart, Two handed chart, multiple activity chart, man machine chart. Flow
diagram and string diagram
 • Micromotion and Memo motion study: Using therbligs, principles of motion
economy.

• Work measurement techniques: Direct time study, synthesis method, analytical

estimating, PMTS, work sampling or activity sampling.

• Time study: Objective, procedure, selecting the job, selecting the worker,
conduct stop watch time study. Find various allowances like relaxation allowance,
contingency allowance, process allowance and special allowance, derive the
standard time.

• Synthesis method: Advantages and application, analytical estimating, procedure.

• Predetermined Motion Time System ( PMTS): Advantages and disadvantage,

Type of PMTS, Method Time Measurement, work factor, Basic motion time.

• Work sampling: Uses, procedures, steps in work sampling, principles involved

in work sampling.

Unit -3

• Product planning: Factors to be considered in product planning, which includes

marketing factor, product characteristics, economic analysis and the production
factor. Problems in lack of product planning.

• Value Analysis: Objective, FAST diagram, Various phases involved in value

analysis which includes, introduction phase, documentation phase ,
recommendation phase, evaluation phase, analysis phase , conclusion phase etc.

• Process planning and routing: Manual process planning and computer aided
process planning, important consideration for process planning, which includes
 manufacturing specification, determination of raw material and selection of
machine tool.

• Prerequisite information for process planning: It includes, product data,

production volume, quality, available equipment and personnel, available time ,
standard time, sequence of operation, material specification.

• Steps in process planning: Preparation of drawing, make or buy decision,

selection of manufacturing process, machine capacity, machine selection,
selection of material, bill of material, selection of jigs and fixtures, operation
planning and tooling requirements, preparation of documents and preparation of
operation sheet and route sheet.

• Quantity determination in batch production, problems: Stock control,

definition of batch size, minimum cost batch size , Raymond’s formula, maximum
return , maximum rate of return.

• Machine capacity, balancing: Line balancing, Variation of time efficiency,

balancing to meet demand, estimating capacity, modifying time efficiency, multi
product analysis, graphical representation, analysis by linear programming.

Unit -4

• Production control system, loading and scheduling: Basic scheduling

problems, production loading, multi product scheduling in batch production,
product sequencing, minimum processing time.

• Batch production scheduling: Sequence of batches, optimizing the production

schedule, maintaining the stock level, specifying batch sizes, minimum cost per
unit, maximum profit for whole schedule, maximum return to the whole schedule,
deriving a realistic solution.
• Scheduling techniques: Forward scheduling, Backward scheduling, stages in
scheduling, loading, dispatching, finite and infinite loading, load chart ( Gantt
chart) , priority sequencing.

• Sequencing rules: Single point sequencing rules, dynamic sequencing rules,

basic scheduling problems .Scheduling and controlling production for delivery
schedules, line of balance method.

• Material Requirement Planning( MRP or MRP-1): Objective flow chart,

general overview, operation of MRP system, definition and terms used in MRP
system, MRP inputs, Issues in MRP, potential benefits from MRP,
Implementation in MRP, Problems in designing and managing the MRP system,
Evaluation of MRP. KANBAN, Dispatching, Progress routing and expediting,
manufacturing lead time , Techniques for aligning completion time and due dates.

Unit -5

• Inventory Control: Purpose of holding the stock, functioning of inventory

control, effective running of stores, Technological responsibility for the state
of merchandise, stock control system.

• Effect of demand on inventories: Effect of a demand impulse on

requirement in successive periods, restrictive on output increase, fluctuation in
distribution channels, stock control system.

• Ordering procedures: Two bin system, ordering cycle system, combination

of two bin system and the ordering cycle systems. Reorder quantity, Reorder
range, Effect of splitting and order.
• Reorder procedure: Reorder point in the two bin system, reorder procedure
in the cycle system, effect of uncertainty, comparison of replenishment
policies, optimistic, realistic and pessimistic policies.

• Determination of Economic order quantity: Economic lot size, ABC

analysis. Introduction to computer integrated production planning system,
Elements of JIT system.

• Fundamentals of MRP-II: From MRP-I to MRP- II, Evolution of MRP-II,

closed loop MRP.

• ERP: Functioning of ERP, features of ERP, scope and benefits of ERP,

applications of ERP, selection of ERP package.