PRODUCTION PLANNING AND CONTROL

1) Routing
Definition 1: -
According to James L. Lundy, the production routing is defined as planning of exact sequence of
workstations to be used in processing a part of the product.
Once the layout has been established, the routing of an item is the determination of the path that the items
must follow as it is manufactured.
Definition 2: -
It describes the sequence of activities to be undertaken in producing a product. The information about all
these activities is mentioned in a separate sheet called route sheet or operations layout.
Definition 3: -
It refers to the planning of sequence in which the material/process would flow. Production planning is one
of the most important function of the management.
Limitations: -
 Few sales managers assume that routing will decrease the flexibility and initiatives of sales force
especially, when the customer needs and marketing environment differs.
 The cost of material handling increases due to long routes.
2) Applications: -
Routing is considered as one of the major functions in PPC department.
It determines the exact sequence of operations to be carried out in process of production which further
creates a path or a route for flow of material from raw material stage to finished product stage.
Some the application of routing are as follows,
1. Transportation
2. Industrial manufacturing
3. Urban planning
4. Sociological studies
5. Decision science
6. Chemistry and medicine
7) Factors affecting routing procedure: -
An organisation may consider the following elements/factors while selecting routing decisions,
1. Form and shape of material
2. Make or Buy decision
3. Production operations plans
4. Routing layout
5. Planning of operations
6. Assembly line planning
7. Line of Balance (LOB)
 8. Break down across the assembly line
9. Modular production
10. Use of robots/ automated production.
11) Routing
Definition: - Q1 only definition, Q2 first two lines, next
It refers to the selection of the path in which usually each part of the product will take into account
while being transformed from raw materials to finished products.
Objectives: -
The main objective of routing is to select best and cheapest way in carrying out a job. Following are the
some of the objectives of routing,
 To easily understand the sequence of manufacturing operations.
 To strictly follow the determined sequence.
 To reach best and cheapest sequence of operations
 To affect design & factory layout building with an aim to secure quick and better production out
comes.
 To affect the plants installation in the factory with an aim to secure best results.
Advantages: -
 Always there is well designed and well assigned division of labour.
 The production of goods is as per the schedule.
 There is often maximization of productivity.
 The factors of production are utilised optimally.
13) Routing procedure: -
The key steps involved in routing are as follows,
1. Product analysis
2. Make or buy decision
3. Requirement of raw material
4. Determining the manufacturing operations & their sequence.
5. Determine the lot size
6. Determine the rejections
7. Determine the product cost
8. List the machines
9. Analyse the time for each operation
10. Preparing the route sheets.
12) Explain how the routing differs in job order, continuous and intermittent production systems?
(or)
Does routing procedure of job shop production system differ from batch production system? Explain?
 (Refer only differences between job shop and intermittent/Batch production systems)
A) Differences between routing in job shop and intermittent production systems: -
Some of the differences between routing in job shop system and batch production are as follows: -
S. No. Routing in job shop production system Routing in intermittent/Batch production sys
1 Complicated task Simple
2 The operations may vary from job to job as The operations and their sequences may vary
every job is new and specifications of from batch to batch.
individual orders are also different.
3 Route sheets are prepared for each order. Route sheets are revised whenever there is a
change in production of the batch.
Differences between routing in intermittent production systems and continuous production systems: -
Some of the differences between routing in Intermittent/batch production system and continuous
production system are as follows: -
S. No. Routing in intermittent/Batch production sys Routing in continuous production systems
1 simple Simplest
2 Equipment is arranged in process type of Equipment is arranged in product type of
layout. Thus, routing is quite complex when layout. Thus, routing follows smooth and
compared to continuous system. continuous procedure.
3 The operations and their sequences may vary The operations and their sequences can be
from batch to batch. standardised.
Differences between routing in job shop and continuous production systems: -
Some of the differences between routing in job shop system and continuous production system are as
follows: -
S. No Routing in job shop production system Routing in continuous production systems
1 Complicated task Simplest
2 Product mix and product specifications are Product mix and product specifications are
highly variable (wide scope of variation). less susceptible to changes (narrow scope of
variation).
3 It depends upon nature of job. Independent.
4 Depending upon the scale of operations, manual Computerised
route sheets are used.
5 It uses general purpose equipment’s. Specialised equipment’s
6 Routing is intermittent Continuous
7 It is applicable to firms producing standardized Customized products or a variety of services.
products or one type of service.
8 Routing follows complex and confusing routing follows smooth and continuous
procedure. procedure.
9 Jobs may or may not use all the machines All machines located in plant are used in
located in the plant. performing each and every operation.

3) Scheduling: -
 Scheduling is the process of arranging a production line for manufacturing the products on time
effectively with less use of time and with optimum utilisation of materials.
(or)
According to Sprigel and Lansburg, scheduling involves establishing the amount of work to be done and
the time when each element of the work will start.
Objectives: -
 To reduce the wastage of time between departments & work centres so as to maintain uniform
loading of all the machines in production line.
 To make effective utilisation of resources so that the output can be produced with in stipulated time
period, there by promptly delivering the products on time.
 To reduce the idle time of labours and machines which may be observed due to delays in movement
of materials, inspection process & in achievement of tasks.
 To set the delivery dates for different manufacturing activities and for finished products.
 To improve the efficiency of production or to improve the productivity.
10) Applications of scheduling: -
1. Production and transportation planning
2. Vehicle routing
3. Planning of sport events
4. Time tabling
5. Scheduling of job shop
6. Scheduling of aircraft
7. Frequency assignment etc.
4) Why scheduling is essential?
A) The scheduling is considered as important function in PPC dept for the following reasons,
1. It is tool that helps a company in providing real time, accurate schedules, decision support and
available-to-promote data in quantities.
2. It is a decision-making process which plays an important role in both manufacturing & service
industries.
3. It ensures effective utilisation of machines, eliminates idle time, reduces inventory and improves on-
line delivery.
4. It helps in determining the time sequence of jobs, tasks, orders, operations and in allocating resources
to achieve the same.
5. It helps in minimizing the production cost and in delivering the products on due dates.
22) Define schedule & scheduling? Objectives? Relation b/t routing & scheduling? Discuss the factors affect
scheduling?
A) Schedule: -
It is a plan or a time table which describes what dept or m/c should do what and when.
 Scheduling: - Q3
Objectives: - Q3
Relationship b/t routing & scheduling: -
They are closely interrelated with one another. Both are interdependent. In other words, routing cannot
be undertaken w/o scheduling and vice-versa. Without routing information, scheduling cannot be done
effectively. Routing is one of the most imp factor on which scheduling depends. Routing determines what
work has to done, where it has to done & how it will be done. And with-out all this information, scheduling
the work would be a difficult task. Both are equally important for one another. For carrying out routing
effectively, schedules prepared in the past are used as basis. These are important functions of PPC.
Thus, in conclusion we can say that these are interrelated, interconnected & independent. The absence
of one, makes the other task ineffective & difficult.
Factors affecting scheduling: - It is influenced by the following factors,
1. External Factors: - The external factors which hold an impact on scheduling includes,
i. External demands of the customers
ii. Delivery dates of the customers
iii. The stock of goods which are remaining with the Dealers and Retailers
2. Internal factors: - The internal factors which hold an impact on scheduling includes,
i. The stock of finished goods which remains with the organisation
ii. The equipment & machinery which is available with the firm along with their total capacity &
specifications.
iii. The quantity of materials which are available with the firm & their specifications.
iv. The number, type and nature of skills available with the firm.
v. The time required for producing finished goods from raw materials or for producing the
component parts for the final assembly of equipment.
vi. The extent of feasibility of production runs.
23) Forward scheduling: -
This method determines the earliest date on which the operation starts and subsequent operations starts
on a date ascertained by adding the lead time of previous operation.
When the last operation is performed, the due date of it becomes the due date of complete order.
This technique is adopted by shop-floor-control system to determine the due date.
The following figure depicts the forward scheduling,
Figure: - forward scheduling
Advantages: - flexible and max utilisation of labour
Backward scheduling: -
Here the order completion date is first ascertained and then sequence of operations are carried out in a
back-ward manner.
 The lead-time of completed activities is subtracted to decide the due date of each operation and finally
the latest possible order start date.
The following figure depicts the backward scheduling,
Figure: - backward scheduling
Advantages: -
1. Operations emphasize on customer due dates.
2. Raw materials are used only when they are required. This saves cost involved in value addition
process.
24) Stages involved in scheduling: - Loading & Dispatching
1. Loading: -
 It is the process of determining which job must be assigned to which work centre.
 It deals with assignment of jobs to specific work centre that have to be performed during a
scheduling period.
 It is also called as shop loading.
Loading procedures classified into 2 types
A. Finite Loading: - and B. Infinite loading: -
2. Dispatching: -
 Process of sequencing & selecting the jobs which are waiting at different work centres when the
capacity is available for processing.
 It helps the operations manager to get awareness regarding the jobs that need to be performed.
Advantages of Scheduling: - (q4 and 3)
 Helps in understanding the project.
 Corrective actions can be taken against delays.
Dis-Advantages of Scheduling: -
 It leads to frequent employee absenteeism & increased inefficiency of labour due to the lack of
relevant skills and experience.
 Resource constraints leads to decline in capacity and there by delay the supply of materials.
 It does not give accurate & up to date information about the lead time, operation time, lot size,
existing load on machines and work centres.
 It leads to machine loading and line balancing problems.
5) Importance of Route sheet: -
Following points highlights the importance of route sheet,
1. It is a tool that helps the production management in converting a raw material into finished product.
2. It shows the sequence of each & every operation with specified time & instruction.
3. It provides a progress card for entire production cycle i.e., from purchasing of raw material until the
production of finished goods.
 4. It records the information that are used to control the passage of specified part of production
throughout the industry.
6) The differences between route card & route sheet are as follows: -
S. No. Route card Route sheet
1 It graphically represents materials used and It is a tool which helps the production
their progress. management in converting of a raw material
into finished goods.
2 It also indicates the percentage allowance for It lays down the precise route through which the
spoilage so that exact amount of materials product would flow during process of
needed can be arranged. conversion. It also defines every step of
production operation.
3 It contains the following information: 7. Department (or Q15 information)
1. Operation number 8. Machine to be used
2. Machine number 9. Sequence of operation with description
3. Jigs and fixtures to be used. 10. Jigs/fixtures required for operations
4. Setup time and operation time 11. Setup and operation time
5. Material used 12. Materials used & specifications
6. Tools to be used for operations 13. Type of tools required for operations
14. Detailed drawings of parts
4 It accompanies with the job throughout all It deals with specific production order.
operations.
5 It is prepared by process engineers. It is generally made from operation sheet.
6 It helps the operator to decide sequence of It helps the operator to decide the department,
operations, machines to be used, materials to machine on which the work is to be done,
be used, tools to be used etc. sequence of operations etc.
7 For routine jobs, printed route cards are When a component is purchased and supplied to
prepared and supplied to the production shop. assembly, an entry is made in route sheet.
15) Describe route sheet with a suitable example.
(or)
Define route sheet. What is the information it contains? Explain it by drawing a route sheet? (route sheet,
information, example)
(or)
Explain the steps involved in preparation of route sheets? (steps + information)
(or)
Explain the general procedure involved in preparing route sheet? (steps + information)
A) Route sheet: - Q5,6
Steps involved in preparation of route sheets: -
PPC department takes the following steps to prepare a route sheet,
Step 1: - It determines how different operations in production/process are related to each other.
 Step 2: - It determines what sequence should be followed for these operations.
Step 3: - It selects the operations essential for processing the product and lists them in their sequence on
Route sheets.
Information contained in a route sheet: -
A route sheet contains the following information,
1. Comprehensive drawing of parts or sub-assemblies or final assemblies.
2. The specifications about quality.
3. The operations sequence to be considered at each work centre.
4. Any equipment or machines to be used.
5. The requirement of tools, jigs, fixtures for the operation.
6. Cutting speed, feed, depth of cut etc for carrying out operations on machine tools.
7. The setup of machine and operation time standards.
8. For completion of operation for the lot size, the time for setup per piece and total time is
examined.
9. It uses metrology gauges for inspection, inspection instructions etc.
10. The handling and packing instructions.
Uses of route sheets: -
 It shows the exact sequence of all operations along with their operation instruction and allowed time.
 It acts a progress report for the part in complete cycle of operation for stock to completion and
delivery to stores.
16) Define & explain the following: route card, work sheet and operation sheet?
(or)
Discuss different routing procedure.
A) The important routing procedures or techniques are as follows,
(a) Route card: - Q6
(b) Work sheet: -
It usually includes the following,
1. All the details are to be considered while manufacturing
2. The routing instructions about each part with identification machines & work place of
operation.
3. However, this sheet is made for manufacturing and maintenance.
(c) Operation sheet: -
 It involves a final sequence of operations.
 It is a step which is implemented before machine loading.
 It includes part number and time, material specifications, description of operations and type of
machines used, tools used & time allocated for setting and performing the operations.
 2 -3 lines matter.
 Due to this difference, often production planning department use a combined sheet as follows,
8) Bill of materials (BOM): -
Definition: -
Bills of material is not merely a material list, but it is that material list which supplies the useful
information for reconstructing the production process.
It is also known as “product structure file”
It consists of sequence of levels, which shows the final of manufacture of the end product.
Highest level of BOM indicates final assembly or final end product.
2nd para: -
Each product possesses BOM which contains complete information about the finished products, quantity
of material used in each product, structure of products.
It is one of the major components of Material Requirement Planning (MRP).
19) Explain the concept of BOM in detail (or)
What do you mean by BOM? Explain in detail? (or)
Explain the BOM with design specification chart? (or)
What is BOM? Discuss various steps involved in it? (BOM + steps)
A) Bill of Material (BOM): - Q8 next para
It is an efficient methodology, which shows the complex product structure at different levels by using
codes. Modular BOMs are widely used to depict the product structures of different kinds.
Steps involved in BOM: -
Bills-of-Material (BOM) involves the following steps: -
Step 1: - Identifies the main elements required in manufacturing or producing a finished product or final
Product.
Step 2: - outlines the various required sub component items
Step 3: - Designs precise and clear process with respect to quantity required for producing a single
Product/unit and work centres involved in this process.
Step 4: - Finally, it gathers the data from product design components, work-flow analysis & other
Recognised manufacturing & industrial engineering documentation.
BOM in Assembly production: -
It (BOM) involves the assembling or gathering the elements and its sub elements, for producing a
finished product. Next 5 lines matter. A product structure tree provides a pictorial representation of sub-
elements and components required for producing a product.
The illustration given below for producing a table shows an assembly diagram and product structure tree.
Figure: Assembly diagram & product structure tree for manufacturing a table.
Product structure tree clearly shows the way in which BOMs are used, for ascertaining the quantities of
each requirement for producing the expected number of end products.
Explanation: -
20) What do you understand by BOM? Why they are prepared and explain with an example?
(or)
Write short note on BOM with an example?
A) Bill of Material (BOM): -
It is a document which is usually prepared by the various departments such as design or engineering or
PPC department.
This document involves the quantity that is needed for such experiments.
Reasons for preparing a BOM: -
1. It helps in evaluating direct material cost when quotations are submitted.
2. It acts as a guideline for production department.
3. It helps to meet the requirements of purchase dept while purchasing the materials.
4. It helps in accounting the consumed materials as the required data can also be used to related jobs
or processes.
5. It operates as one of the controlling techniques.
Usually, 4 copies of BOMs are prepared form which each copy is passed on to the production, stores,
and cost accounting departments and the remaining one copy is maintained by the planning or
engineering department.
Example: - The specimen of BOM is as follows,
21) What is the role of BOM? How demand affects the BOM? (or)
Explain the importance of BOM in production line. (Role/ importance)
A) Role or Importance of BOM: -
BOM plays a significant role in the PPC. Its significance can be understood with the help of following
points: -
1. BOM provides authorisation to various depts of the organisation. For instance,
 It provides authority to purchase dept for requisition of purchases.
 It provides authority to production dept for requisition of materials.
 It provides authority to shop keeper for issuing material.
2. It helps in controlling the use of material for those jobs which are non-standardised.
3. It is a format through which material procurement planning can be easily made.
4. It helps in preparing quotations for various jobs.
5. Efficient BOM reduces the work stoppage due to non-availability of material.
6. It plays prominent role in job costing and production planning.
From the above points, it can be concluded that BOM is an effective technique which may help to
control the production process of a manufacturing organisation.
Affect of Demand on BOM: -
Inventory can be categorized into 2 types: 2 independent demand & dependent demand.
Independent demand refers to the demand for finished product.
 Dependent demand is the demand for component parts or sub-assemblies.
A BOM is a pictorial representation showing the relation-ship between quantities. BOM shows the
relationship b/t independent & dependent demand.
The following figure depicts BOM: -
figure: - Bill of Materials (BOM)
In the figure, Item-A is an independent demand item. Whereas other items are dependent demands. Two
units of ‘B’ are combined with one unit of ‘C’ To make the final product ‘A’. one unit of ‘D’ makes 2 units
of ‘B’ and 1 unit of ‘E’ combined with 2 units of ‘F’ makes 1 unit of ‘C’.
9) Importance of loading: -
Following points depicts the importance of loading,
1. It deals with assigning of jobs to specific work centres.
2. It is used to determine which job must be assigned to which work centre.
3. It is an important stage of scheduling.
4. It helps to provide optimum utilisation of resources.
5. It reduces idle time.
25) Loading: -
Q24 about loading + routing + scheduling
Example: -
 A manufacturing company allocates some amount of work to a machine which is available on
the shop floor for 168 hours a week.
 However, it does not mean that the work of 168 hours can be loaded on to that machine.
 Because, there are many things that may interfere in the work and consume this available time.
 Ex: - Machine is not used on holidays, weekends & some times cleaning may be required
between operations etc.
Scheduling: - Q3 definition
Example: - A micro electronics manufacturing company determining the production levels up to a year in
advance by arranging the machines and man power for a specified period of time.
Differences between Loading & scheduling: -
The differences between Loading & scheduling are as follows: -
S. No. Loading scheduling
1 The relation ship existing between load & It deals with the performing operations to
capacity of work centres is known as Loading. proceed at right time & determining starting &
completion time of each operation.
2 It is concerned with fixing sufficient capacity It undertakes the task of completing the
for production planning or utilising spare operations on time.
capacity for some other work.
3 It deals with proper utilisation of machines It is a difficult task when compared to loading
based on their capacity & to fulfil the task for a as it focuses on efficiency of plant, manpower
 given production plan.
4 For machine loading, proper allowances are to
be prepared such as set up of machines, process
adjustment & maintenance down time etc.
5 Loading activities are used in scheduling.
& equipment.
Machine loading allowances constitute data &
are continuously used for proper functioning
of scheduling.
It ensures proper utilisation of all the activities
so that the operation is effective.

Unit-6 Dispatching
1) Dispatching: -