REDUCTION OF WASTAGES THROUGH PPC TECHNIQUESMADE BY: MUHAMMAD ASIM ASLAM (IN-06)

WHAT IS PPC??? A production planning and control is concerned with planning

and controlling all aspects of production , including materials,

scheduling machines and people, and coordinating suppliers and

customers.

Production Planning is mainly concerned with the following important issues:

What production facilities are required? How these production facilities should be laid down in the space

available for production? How they should be used to produce the desired products at the

desired rate of production?

Production control is a mechanism to monitor the execution of the plans

OBJECTIVES OF PPC Process efficiency

Develop team spirit

Effectiveness of work

Ideas for new method

Reduce cost

Reduce time

Reduction of wastages

FUNCTION OF PPC & TECHNIQUES APPLIED ON FUNCTION

PLANNING ROUTING LOADING SCHEDULING DESPATCHING FOLLOW UP

S.No Function Definition Technique.

`1 Planning Mental reaction before action.

PESTEL analysis Stakeholder analysis Competitor analysisNeed and gap analysisMRP , MRPII, ERP

2 Routing. Selection of path. Network modelingi) CPMii) PERT Route sheet

Loading 

Assign job to men or M/S.

Various Loading chart.

4 Scheduling Program of operation.

Gantt chart.

5 Dispatching Release of orders. i) card system

6 Follow up regulates the progress of production process.

Control board Line of balance.

PLANNING

Planning is simply thinking before action.  Planning is deciding in advance what is to be done in future. An organizational set up is created to prepare plans and policies Various charts, manuals and production budgets are also

prepared. Planning provides a sound base for control.

TECHNIQUES USED IN PLANNING FUNCTION:

PESTEL analysis

Stakeholder analysis

Competitor analysis

Need and gap analysis

PESTEL ANALYSIS Identify key trends in the external environment that will have the greatest

impact on the organization and its strategy: 

Political trends Economic trends Social trends Technological trends Environmental trends Legal trends

STAKEHOLDER ANALYSIS Identify key stakeholders - internal and external Define information required about each group Gather by interview and questionnaire Analyze results Review their requirements against current objectives

COMPETITOR ANALYSIS

NEED AND GAP ANALYSIS  A technique that businesses use to determine what

steps need to be taken in order to move from its current state to its desired, future state.

Need and Gap analysis consists of 1. listing of the present situation ("what is")2. listing factors needed to achieve future objectives ("what should be")3. Highlighting the gaps that exist and need to be filled.

Pictures of need and gap analysis

MRP(material Requirement Planning)

Material requirements planning (MRP) is a production planning, scheduling, and inventory control system used to manage manufacturing processes.

Most MRP systems are software-based, while it is possible to conduct MRP by hand as well.

MRP systems use four pieces of information to determine what material should be ordered and when order should be placed

I. master production scheduleII. Bill of materialsIII. Production cycle times IV. Supplier lead times

MRPII(manufacturing resource planning)

Manufacturing resource planning (MRP II) is defined as a method for the effective planning of all resources of a manufacturing company

It integrates planning of all aspects (not just production) of a manufacturing firm MRP-II includes functions such as business planning, production

planning and scheduling, capacity requirement planning, job costing, financial management and forecasting, order processing, shop floor control, time and attendance, performance measurement, and sales and operations planning

ERP(Enterprise Resource Planning)

Enterprise resource planning (ERP) is business management software—usually a suite of integrated applications—that a company can use to collect, store, manage and interpret data from many business activities, including:

Product planning Manufacturing or service delivery Marketing and sales Inventory management Shipping and payment

SOME SCREEN SHOTS OF ERP SOFTWARE

MRP Vs MRPII Vs ERP MRP stands for material requirements planning and deals with bringing

in the right amount of raw material at the right time to support production

MRPII stands for manufacturing resource planning and builds on MRP by adding shop floor production planning and tracking tools.

A third-generation system available at time of publication is called ERP, or enterprise resource planning, which integrates all departments of the business, not just manufacturing and purchasing.

ROUTING Routing is determining the exact path which will be followed in production.  It is the selection of the path from where each unit have to pass before reaching

the final stage In the words of ALFORD and BEATY:

“Routing is the specification of the flow sequence of operations and processes to be followed in producing a particular manufacturing lot.”

TECHNIQUES USED IN ROUTING FUNCTION: Network modeling techniques CPM PERT ROUTE SHEET

CPM (CRITICAL PATH METHOD) A sequence of activities is called a 'path The longest-path in the diagram is the critical path

and it assume deterministic time . It is 'critical' because all activities on it must

be completed in the designated time, otherwise the whole project will be delayed.

PERT It shows the time taken by each station for manufacturing a product and

the total time required for its completion. It lays down their proper sequence, relationships, and duration in

the form of a network.  Lines connecting the events are called paths and the longest path

resulting from connecting all events is called the critical path. The length (duration) of the critical path is the duration of the production of any product.

It uses probabilistic time approach , in which three types of estimated time occur like,

I. optimistic timeII. Most likely timeIII. Probabilistic time

optimistic time (O): the minimum possible time required to accomplish a task, assuming everything proceeds better than is normally expected

pessimistic time (P): the maximum possible time required to accomplish a task, assuming everything goes wrong.

most likely time (M): the best estimate of the time required to accomplish a task, assuming everything proceeds as normal.

expected time (TE): the best estimate of the time required to accomplish a task, accounting for the fact that things don't always proceed as normal

TE = (O + 4M + P) ÷ 6

EXAMPLE OF PERT CHART

ROUTE SHEET A document accounting for the output of production and tracing the sequence of operations of 

a batch of manufactured components.

Theroute sheet is used in serial and especially individual production to show the workers output, calculate the wages of the workers, and exercise operative super-vision of the movement of parts in production

  It contains standardized data (such as time standards andcost) and information about the actu

al movement of the manufactured components and about the workers’ output in each operation.

LOADING It is important that machine should be loaded according to their

capabilities performance the given and according to the capacity.

It is concerned with preparation of machine loads and fixation of starting and completion dates for a particular operation

Techniques used in loading function: Loading charts

LOADING CHART:A chart showing the amount of work still to be performed by a factory producing unit such as a machine or assembly group.It shows you how much the machine is rated to lift at specific points of the lift under ideal conditionsA load chart is the most important chart you must understand before operating a piece of machinery 

SHEDULING Scheduling is the determining of time and date when each operation is

to be commenced or completed. The time and date of manufacturing each component is fixed in such a

way that assembling for final product is not delayed in any way.

In the words of KIMBALL “The determination of the time that should be required to perform each operation and also the time necessary to perform the entire series, as routed, making allowances for all factors concerned”

Techniques used in scheduling: GANTT CHART: It is a Type of bar-chart that shows both the scheduled and completed work over

a period A time-scale is given on the chart's horizontal axis and each activity is shown as a

separate horizontal rectangle (bar) whose length is proportional to the time required (or taken) for the activity's completion.

DISPATCHING Dispatching is concerned with starting the processes & operations of

production. Dispatching is based on the route sheets & schedule sheets.

In the words of JOHN A. SHUBIN“Dispatches put production in effect by releasing and guiding manufacturing order in the sequence previously determined by route sheets and schedules”.

Techniques used in Dispatching:

Card system

CARD SYSTEM : At the beginning of a work day, the resource's identifier or other information is handwritten on the card. Each time the resource's status changes, the card is punched in the time clock and a new status entry is handwritten on the card. The card collects a series of entries through the work shift.

FOLLOW UP

 It regulates the progress of materials and part through the production process.

The follow up procedure is used for checking the progress. It removing the bottleneck in the production line.

Techniques used in Follow up Control board. Line of balance.

CONTROL BOARD: The hourly production control board, otherwise known as the hour by hour chart, is used to monitor the progress or output of a process against plan

LINE OF BALANCE:Line Of Balance (LOB) is a management control process for collecting, measuring and presenting facts relating to time, cost and accomplishment - all measured against a specific plan.It shows the process, status, background, timing and phasing the activities.

To do LOB, the following is needed: I. A contract schedule, or objective chart;II. A production plan or lead-time chart for the production process itself;III. A program status chart on which to plot LOB and the cumulative

quantities of units that have passed through the control points of the assembly/production process.

WHICH WASTAGES REDUCED IN COST??

Carrying costTransportation costMaterial handling costLoss of customer Rejection costRework costLost of production costDirect labor costIndirect labor costInspection cost

WHICH WASTAGES REDUCED IN TIME???

Machine idle time

Worker idle time

Machine down time

Order delivery on right time

After rejection rework time

Setup time