Chap-04-Production Planning & Control

8/11/2019 Chap-04-Production Planning & Control

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Chapter-04:

Production Planning and Control

1. Definition of Production Planning

In any business that produces a product or service, production activity must be related to

market demand as indicated by continuous stream of customers orders. For maimum

effectiveness, this must be done in such a !ay that customer demands are satisfied, but at the

same time production activities are carried on in an economic manner. "he process of

developin# this kind of relationship bet!een market demand and production capacity is the

function of production plannin#.

2.Definition of Production Control

$roduction control is defined as the desi#n and use of a systematic procedure for establishin#

plans and controllin# all the elements of an activity. $roduction control includes:

% complete plan&

% follo! up procedure for determinin# ho! closely the plan is follo!ed&

% means of re#ulatin#, eecution to meet the plans re'uirements.

3. Objectives Production Planning

"he main ob(ectives of production plannin# are:

i. "o determine the capacity of all manufacturin# departments&

ii. "o find !ay and means throu#h !hich product manufacturin# re'uirement, such as

materials and their necessary components !ill be available in the ri#ht 'uality and

'uantity at the ri#ht time.

iii. "o maintain accurate record of all materials and component stock.

4. Steps of Production Control

"here are four steps of production control:

i. Routing

)outin# may be defined as the selection of paths or routes over !hich each product is

travel in bein# transformed from ra! material into finished products. In other !ords

routin# determines the specification of the flo! or se'uence of operations and

processes to be follo!ed in producin# a particular manufacturin# lot.

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Procedure of Routing:

"he routin# procedures are as follo!s:

a. %n analysis of article to determine !hat to a!eand !hat to bu".

b. %n analysis of article to determine !hat materials are needed.c. % determination of the manufacturin# operation and their se'uence.

d. % determination of lot si+e.

e. % determination of scrap factors.

f. %n analysis of the cost of article.

#. "he or#ani+ation manufacturin# forms.

ii. Sc#eduling

chedulin# is the task of determinin# !hen each operation is start and finish.

chedulin# is the heart of production control because it inte#rates the !ork of other

departments to produce a complete product at the promised date.

$ec#ni%ues of sc#eduling:

"he basic schedulin# techni'ues are:

a. &antt C#art

enry . /antt developed a versatile chartin# techni'ue. It enables a

mana#er to initially schedule pro(ect activities and than to monitor

pro#ress overtime by comparin# planned pro#ress to actual pro#ress.

4 1 2 *0 * *4 *1 *2 0

*

3

4

1

5

26

Fi#. /antt chart

b. 'lo( C#art

"his !as developed by the /ilberths to represent the planned se'uential

relationship of !ork performance. Flo! chart indicates the relationship

bet!een various activities.


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c. )ine *alancing

"his method !as developed by 7.. 8avy durin# the econd 9orld 9ar.

ine balancin# is a techni'ue of product layout. "he !hole production

process is called here a line and the techni'ue used to allocate the !ork

elements in various !ork station so that no e'uipment stay idle is calledline balancin#.

d. P+R$ , CP-

$)" ;$ro#ram valuation and )evie! "echni'ue< and C$= ;Critical

$ath =ethod


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Practical Proble/1:

"he follo!in# table #ives the activities in a construction pro(ect and other relevant

information:

0ctivit" Duration* @ 0

*- 3

- 3 *0

- 4 *

3- 4 1

4- *0

Re%uireent:

a< ?ra! the 8et!ork of the pro(ect&

b< Find out the Critical $ath&

c< ?etermine the lack for each path&

d< ?etermine the arliest tart and Finish "ime and atest

tart and Finish "ime.

a ;* - 3< 3 0 0 B 3 3 3 @ 3 0 3

C ; @ 4< 4 4 B 1 2 @ 1 2

? ;3 @ 4< 3 3 B 2 2 @ 3 2

; @ < 4 4 4 B 4 2 *3 @ 4 6 *3

F ;3 @ 1< 4 3 3 B 4 5 *3 @ 4 6 *3

/ ;4 @ 1< 2 2 B *3 *3 @ 2 *3

;1 @ 5< 3 *3 *3 B 3 *1 *1 @ 3 *3 *1

I ; @ 5< 3 2 2 B3 ** *1 @ 3 *3 *1

E ;5 @ 2< *1 *1 B *2 *2 @ *1 *2 ;2 @ 6< *2 *2 B 0 0 @ *2 0

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Proble/3:

GH td. plannin# a pro(ect to introduce a ne! product has listed the follo!in# necessary

available:

0ctivit" ediate Predecessor Duration

% - 1

> - 3

C %

? % 4

% 3

F C 3

/ ?

>,?,

I E I,/,F 3

Re%uireent:


b< Find out the Critical $ath&


d< ?etermine the arliest tart and Finish "ime and atest

tart and Finish "ime.

Solution:

a - *0 * 1

C % 2 6 *0

? % *0 * 0

% 5 5. **

F >,C 6 6 6

/ ? 3 3. 5

,F,/

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)e'uirement:


b< ?etermine the Critical $ath&


d< ?etermine the arliest tart and Finish "ime and atesttart and Finish "ime.

Solution:

a Deterination of +5pected Project $ie

0ctivit"Preceding

0ctivit"

$ie +stiates in (ee!+5pected Project

$ie

te6 178to94t9 tp

-ost

Optiistic

to

-ost

)i!el"

t

-ost

Pessiistic

tp

% - 4 *

> - *0 * 1 *4

C % 2 6 *0 6

? % *0 * 0 *

% 5 5. ** 2

F >,C 6 6 6 6

/ ? 3 3. 5 4

,F,/

Construction of et(or! Diagra:

b< Deterination of critical pat# for t#e project

Pat#s )engt# in $ie

*A A A 1 B 2 B *2

*A A 4 A A 1 B * B 4 B 6

*A A 3 A A 1 B 6 B 6 B 2

*A 3 A A 1 *4 B 6 B 2

%s !e kno!, the critical path is the lon#est path amon# the paths, so *A A 4 A

A 1, i.e. 2 days is the critical path.

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c< Deterination of Slac! for eac# pat#:

Pat#s Slac! Critical Pat#

O(n Pat#

Outcoe

*A A A 1 D 6 @ *2 **

*A A 4 A A 1 D 6 @ 6 0*A A 3 A A 1 D 6 @ 2 0*

*A 3 A A 1 D 6 - 2 0*

d< Deterination of +arliest Start and 'inis# $ie and )atest Start and 'inis# $ie

0ctivit" Duration+arliest $ie )atest $ie

Start 'inis# Start 'inis#

% ;* @ < 0 0 B @ 0

> ;* - 3< *4 0 0 B *4 *4 * @ *4 * *

C ; @ 3< 6 B 6 *4 * @ 6 1 *? ; @ 4< * B * 0 0 @ * 0

;@ < 2 B 2 *3 4 @ 2 *1 4

F ;3 @ < 6 *4 *4 B 6 3 4 @ 6 * 4

/ ;4 @ < 4 0 0 B 4 4 4 @ 4 0 4

; @ 1< 4 4 B 6 6 @ 4 6

Proble/;:

% pro(ect consistin# of ei#ht activities has the follo!in# characteristics:

0ctivit"

$ie+stiate in (ee!

-ost

Optiistic

to

-ost

)i!el"

t

-ost

Pessiistic

tp

* - *4

* - 1 2

- 3 ** 6

- 4 * 4 05

3 - ** *5

4 - *41 - 5 3 6 5

- 2 2

5 - 2 5 *3 3*

Re%uireent:

e< ?ra! the 8et!ork of the pro(ect&

f< ?etermine the Critical $ath&

#< ?etermine the lack for each path&

h< ?etermine the arliest tart and Finish "ime and atest

tart and Finish "ime.The End

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Chap-04-Production Planning & Control