Question

In what ways are the process plans for parts to be made important to the management function of production control? Loading, Scheduling, Combining Functions, Dispatching, Reporting or Follow-Up, Corrective Action, and Replanning.

Answer 1

Functions of production planning and controlling is classified into:

1. Pre-planning function
2. Planning function
3. Control function

PRE-PLANNING FUNCTION

Pre-planning is a macro level planning based upon the forecasted demand, market analysis and product design and development. It deals with analysis of data. This stage is concerned with process design such as new processes and developments, workflow (Plant layout).

PLANNING FUNCTION
The planning function starts once the task to be accomplished is specified, with the analysis of four M’s, i.e., Machines, Methods, Materials and Manpower. Standardization, simplification of products and processes are given due consideration.

CONTROL FUNCTION
Control phase is effected by dispatching, inspection and expediting materials control, analysis of work-in-process. Finally, evaluation makes the PPC cycle complete and corrective actions are taken through a feedback from analysis. A good communication, and feedback system is essential to enhance and ensure effectiveness of PPC.

Parameters for PPC
The functions of PPC can be explained with the following parameters:

1. Materials: Raw materials, finished parts and bought out components should be made available in required quantities and at required time to ensure the correct start and end for each operation resulting in uninterrupted production. The function includes the specification of materials (quality and quantity) delivery dates, variety reduction (standardization) procurement and make or buy decisions.
2. Machines and equipment: This function is related with the detailed analysis of available production facilities, equipment down time, maintenance policy procedure and schedules.
3. Process planning (Routing):
   It is concerned with selection of path or route which the raw material should follow to get transformed into finished product. The duties include:
   
   1. Fixation of path of travel giving due consideration to layout.
   2. Breaking down of operations to define each operation in detail.
   3. Deciding the set up time and process time for each operation.
4. Estimating:
   Once the overall method and sequence of operations is fixed and process sheet for each operation is available, then the operations times are estimated. This function is carried out using extensive analysis of operations along with methods and routing and a standard time for operation are established using work measurement techniques.
5. Loading and scheduling:
   Scheduling is concerned with preparation of machine loads and fixation of starting and completion dates for each of the operations. Machines have to be loaded according to their capability of performing the given task and according to their capacity.
   1. Loading, the machines as per their capability and capacity.
   2. Determining the start and completion times for each operation.
   3. To coordinate with sales department regarding delivery schedules.
6. Dispatching:
   This is the execution phase of planning. It is the process of setting production activities in motion through release of orders and instructions. It authorizes the start of production activities by releasing materials, components, tools, fixtures and instruction sheets to the operator. The activities involved are:
   
   1. To assign definite work to definite machines, work centres and men.
   2. To issue required materials from stores.
   3. To issue jigs, fixtures and make them available at correct point of use.
   4. Release necessary work orders, time tickets, etc., to authorize timely start of operations.
   5. To record start and finish time of each job on each machine or by each man.
7. Expediting:

It is logical step after dispatching which is called ‘follow-up’. It coordinates extensively to execute the production plan. Progressing function can be divided into three parts, i.e., follow up of materials, follow up of work-in-process and follow up of assembly.

1. Inspection:
   This forms the basis for knowing the limitations with respects to methods, processes, etc., which is very much useful for evaluation phase.
2. Evaluation:
   A thorough analysis of all the factors influencing the production planning and control helps to identify the weak spots and the corrective action with respect to pre-planning and planning will be effected by a feedback.