Content Topic 4 Business Operations 1

22 Production planning and Control

Produksie Beplaning en Beheer ATP, pg.? What should be covered/taught? Which teaching methodology will be employed? How will it be assessed? 3

4 1.Briefly introduce learners to the following concepts: a.Production planning( pay attention to planning; routing; scheduling and loading) b.Production control(pay attention to dispatching; following-up; inspection and corrective action Proposed methodology: Simulation

5 1. Watch the video-clip in connection with the production of the BMW-5 series and comment on the production system in used, degree of Production planning and control carried out in the process. Activity (10 minutes)

6 2. U are employed by “DT Manufacturers’. Simulate the production of magic boxes by using the “production-nets” attached. Pay careful attention to the raw materials; number of workers and components used. Individual tasks; sequencing of tasks; where each tasks will be executed; the route of each process through the factory; time to complete each task; total number of workers needed, machinery/components available and the time that each machine/component will be used. See that proper Production Control takes place. Activity (45 minutes)

7 3. Calculate the productivity of “DT Manufacturers” by completing the accompanying work sheet. 4. Wrap-up the topic by using the following table(see next slide) as a guide. Activity (20 minutes)

88 Loading Production Planning and Control Production PlanningProduction Control Corrective Action Planning Routing SchedulingInspection Following up Dispatching

99 Thank You!

10 Production Planning Scheduling refers to: working out 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. Production schedule Master Schedule Manufacturing schedule Scheduling of Job order manufacturing Loading Execution of the schedule plan as per the route chalked out includes the assignment of the work to the operators at their machines or work places. So loading determines who will do the work, as Routing determines where, and Scheduling determines when it shall be done.

11 Production control is: the process of planning production in advance of operations, establishing the exact route of each individual item part or assembly, setting, starting and finishing for each important item, assembly or the finishing production and releasing the necessary orders as well as initiating the necessary follow-up to have the smooth function of the enterprise. Production control

12 Dispatching Dispatching involves the issuing of production orders for starting the operations. Necessary authority and conformation is given for: 1. Movement of materials to different workstations. 2. Movement of tools and fixtures necessary for each operation. 3. Beginning of work on each operation. 4. Recording of time and cost involved in each operation. 5. Movement of work from one operation to another in accordance with the route sheet. 6. Inspecting or supervision of work Dispatching is an important step as it translates production plans into production. Production control

13 Follow up Every production programme involves determination of the progress of work, removing bottlenecks in the flow of work and ensuring that the productive operations are taking place in accordance with the plans. It spots delays or deviations from the production plans. It helps to reveal defects in routing and scheduling, misunderstanding of orders and instruction, under loading or overloading of work etc. All problems or deviations are investigated and remedial measures are undertaken to ensure the completion of work by the planned date. Production control

14 Inspection: This is mainly to ensure the quality of goods. It can be required as effective agency of production control. Corrective measures Corrective action may involve any of those activities of adjusting the route, rescheduling of work changing the workloads, repairs and maintenance of machinery or equipment, control over inventories of the cause of deviation in the poor performance of the employees. Certain personnel decisions like training, transfer, demotion etc. may have to be taken. Alternate methods may be suggested to handle peak loads. Production control