Chapter 10: Production Planning and Control (PPC)

10.1 Introduction

Production Planning and Control (PPC) is a critical function in manufacturing that ensures resources are used efficiently to produce goods on time, at the right cost and quality. PPC aligns production with market demands by forecasting, scheduling, and monitoring production activities.


10.2 Objectives of PPC

  • Ensure smooth and continuous production flow

  • Optimize utilization of resources (man, machine, materials)

  • Minimize production costs and lead times

  • Improve customer service through timely deliveries

  • Balance demand and supply effectively


10.3 Functions of PPC

  1. Routing

    • Determining the path of workflow from raw materials to finished goods

    • Specifies operations, their sequence, and machines involved

  2. Scheduling

    • Fixing the time for each operation

    • Types: Master Schedule, Operation Schedule, Daily Schedule

  3. Loading

    • Assigning work to machines or work centers based on capacity

  4. Dispatching

    • Issuing orders for production to start on the shop floor

  5. Follow-Up

    • Monitoring production progress

    • Taking corrective actions if delays or bottlenecks occur

  6. Expediting

    • Speeding up production processes to meet deadlines


10.4 Types of Production Systems

  • Job Production – One-off or custom items

  • Batch Production – Groups of items produced together

  • Mass Production – Large-scale, continuous production of standardized products

  • Continuous Production – Highly automated and uninterrupted process


10.5 Production Planning

Production planning focuses on:

  • Forecasting demand

  • Estimating resource needs

  • Preparing production schedules

  • Planning capacity and inventory levels

10.5.1 Types of Planning

  • Long-Term Planning – Strategic capacity decisions

  • Medium-Term Planning – Aggregate planning for 6–18 months

  • Short-Term Planning – Weekly or daily scheduling and execution


10.6 Production Control

Involves the real-time monitoring and control of ongoing production activities to ensure adherence to plans.

10.6.1 Techniques of Production Control

  • Gantt Charts

  • Bar Charts

  • PERT (Program Evaluation and Review Technique)

  • CPM (Critical Path Method)

  • Kanban (in Lean systems)

  • ERP Systems (Enterprise Resource Planning)


10.7 Capacity Planning

Determining the production capacity required to meet changing demands:

  • Design Capacity – Maximum output possible

  • Effective Capacity – Practical achievable output considering constraints


10.8 Line Balancing

Balancing the workload across all workstations to minimize idle time and ensure smooth workflow. Used especially in assembly lines.


10.9 PPC in Modern Industry

Modern PPC integrates:

  • ERP and MRP Systems

  • Automation and IoT

  • Real-time analytics and dashboards

  • AI-assisted scheduling


Conclusion

Production Planning and Control ensures efficient utilization of resources and timely delivery of products. It serves as the bridge between demand and manufacturing, balancing market needs with factory capabilities. Modern PPC is evolving with digital tools, automation, and analytics for smarter and more responsive production systems.


Exercises

A. Short Answer Questions

  1. What is the primary objective of PPC?

  2. Define routing and scheduling.

  3. Mention different types of production systems.

  4. What is line balancing?

B. Long Answer Questions

  1. Explain the functions and importance of production planning and control in manufacturing.

  2. Discuss different types of production systems with examples.

  3. Describe capacity planning and its importance in PPC.

  4. Write short notes on Gantt Chart, PERT, and CPM in production control.

C. Multiple Choice Questions

  1. The function of assigning specific jobs to specific machines is called:
    a) Routing
    b) Dispatching
    c) Loading
    d) Scheduling

  2. Mass production is suitable for:
    a) Customized goods
    b) Unique items
    c) Standardized products
    d) Prototyping

  3. A bar chart used in scheduling is called:
    a) Pareto chart
    b) Gantt chart
    c) Flowchart
    d) Pie chart

Answers: 1–c, 2–c, 3–b

D. Practical Task

Visit a local manufacturing unit or watch a video tour of an automated factory. Prepare a brief report on how production is planned and controlled. What tools and software are used? How are bottlenecks handled?

Comments