1 production control

8/12/2019 1 Production Control

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The function of Production Control is to produce productswith minimum total cost in the required planned delivery

timeframe.

The production plan should permit one to anticipate the

progress of the production of any and every individual productfrom the receipt of the raw material to the shipment of the

order.

The production plan should also permit one to anticipate the

itemized and total cost of producing and delivering goods .

Overview of Entire Production Control System

B F Tech VI,January2012


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The efficiency of the production control performance is equal

to the precision of the time and cost anticipation .

The greater the deviation from the scheduled time and cost

figures, the poorer the production control performance.

Production control is composed of a sequence of five

activities



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1)Analyzing:

Process of determining the quality specifications of the

product.

The analysis provides the specifications for the following

elements of production:

Raw materials

Production equipment and tools

Production personnel that will yield the durability, utility and

emotional appeal (style factors) required for the garment .



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This presents the quality measuring scale for the product.

- The analysis also gives the basis of quantitative production

capacity of each operation, job or process.- This is one of the requirements for forecasting the anticipated

load of production per unit time.



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2) Forecasting:

It is the process of estimating the future sales volume, the rate

of sales and the rate of delivery

3) Planning (Organizing and Scheduling):

Activity of organizing the sequence of communications and

material processing.

Every production process must be initiated or curtailed by

some communication without which there could be no

precision scheduling.

Scheduling is the second half of the planning activity; it adds

the when to organizing what and where



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4)Routing:

It consists of assigning the who to planning and executing the

what, where and when

5)Controlling:

It is the activity with which the production manager inspects

and corrects the execution of the production plan. It is theaction that must be taken to change the plan whenever

production is behind the planned schedule because of

improper planning, unforeseen emergencies or unpredicted

occurrences.



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Production controlinvolves people and activities thatstrive toplan, schedule, coordinate , monitorwork flow

and control production with in manufacturing factory.

Its duties include reviewing master production schedules

and work orders, and revising schedulesaccording toavailability of workers, materials and equipment



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Production controlalso aids the supervisor in guiding his/

her line toward an optimum level of productivityin order

to assure that scheduled completion datesare achieved.

Production controlassures that products are being

manufactured on a balanced and timely program.



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What does a Production Control; system entail?

Generally split into two main subsystem: Production planning and Resource planning

Production Control and Cost Production reporting;

Main objectives of the Production planning system are:

1) To assist in the planning and recording of overall production

requirements.

2) To assist in the translation of the overall requirement in to a

production schedule

3) Material Requirement and planning (MRP) to enable the

user to correctly schedule the ordering of raw materials



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4) Resource Capacity planning to enable the user to analyze

physical capacity of men and machines against capacityrequired.

5) To provide facilities to plan the production schedule in detailand ensure that production resources are fully utilized.

6) To launch production jobs with required documentation (jobcards, Material requisition form, bundle tickets), the materialsrequired to be drawn for these jobs, and the activities to be

performed in the production process

7)To capture and monitor details of work in progress andproduction quantities



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8) To maintain a tracking history of job progress

9) To report an exceptional conditions to ensure that jobs

progress according to plan

10) To capture and record the true cost of production and to

record abnormal costs such as reprocessing costs etc

11)To report on the costs and efficiencies of complete jobs in the

following categories:

12)Planned quantities versus quantities actually produced

The ultimate objective of all these activities is the organizationof the supply and movement of materials and labor, machine

utilization and related activities in order to help manufacture

customer orders (or stock) in the most efficient time , at the

lowest possible cost and with the highest qualityB F Tech VI,January2012


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Functions of Production Control:

Clear distinctions between Production control and actual

manufacturing Methods installed for the organized production control must be

definitely adapted to the particular factories in which they areinstalled

Production control is a facilitating service to manufacturingmanned by staff personnel. It coordinates all of the necessaryproduction information and production aids, includingmethods , times , materials and attachment

It directs and checks on the course and progress of work, and

closes the records when work on an order has been completed. Production control and engineering department has separate

responsibility



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WHY PRODUTION CONTROL?

As customer bases grow, there are more and more stylevariations with in product groups.

Control procedures are determined by several conditioning

factors:

1)Varied or repetitive character of operations

2) Nature of manufacturing processes

3) Magnitude of operations



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1)Varied and repetitive operations:

Variety of operations complicates the problem of planning andcontrol, whereas repetitive operations, since they reducevariety, tend to simplify the problem

Variants between continuous production of a single

standardized product and the completely special orderbusiness on the other



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Manufacturing to order

Manufacturing for stock

Variations in capacity of machines for

different classes of work Degree to which subassembly exists

Occurrence of customer orders containingspecific delivery dates

Receipt of orders for many small lots



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2)Nature of Manufacturing:

Production control is at minimum where a single

homogeneous product is treated by a fixed sequence of

processes in a continuous flow e.g coca cola bottles

Very little production control is required in these factories

since it has already been embodied in the product and

equipment itself



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In contrast to the continuous industries are repetitive operations

in factories making many products and lots at the same time.

To bring these together in proper sequence, at the right time andat the right place pushes planning and control functions to the

utmost.In customer manufacturing, less accurate planning is possible

than when manufacturing for stock.

Custom orders usually require a certain time , over and aboveactual operating time to pass through the factory.



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In mixed stock and custom manufacturing, either stock or

custom orders may be the main feature

A certain amount of stock manufacturing to fill gaps in

machine loading is a useful accompaniment of custom work.



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3)Magnitude of operations:

In a small scale enterprises, control is more informal because itis more personal and direct.

The degree to which the performance of any activity must be

decentralized depends upon the scope of operations and the

convenience of their location.In large factories , activities associated with warehousing,

processing operations and custody of fished goods must of

necessity be carried on in numerous locations.



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Production planning and control

There are certain basic elements in a system or productionplanning and control.

Production forecasting/ planning:

It determines what manufacturing must produce, the quantities

involved , when the products must be available and the timeand quantity requirements for materials , parts, labor and

facilities



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Production control:

Promotes effective factory operation through its control of

activities with in production department itself. This control

may involve routing, the decision on facilities and sequence

for each operation, and follow up. The importance of control functions, and procedures will vary

from factory to factory.



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Routing:

It begins at the determination of the sequence of operations

Routing can be performed properly only be people who arethoroughly familiar with the character of the work to be done

and with the resources available for doing it

Preparation of operational breakdowns and production orders

Loading and scheduling



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Costs and benefits of Production control

Since production control is being paid for, either as a

specialist function or a hidden cost, it is necessary to decide

which method is most efficient.

The production control workload varies in proportion to the

number of orders it processes rather than the hours of

production load .

The costs of poor production control are low rates of

production, high costs, high inventory of materials in process

and finished stock, poor morale and disappointed customers.



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Benefits and advantages of Production control:

1) The Consumers

Increased productivity

Better values

On time deliveries

2) The Producers

Adequate wages

Stable employment

Job security



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Improved working conditions

Increased personal satisfaction

Security of investment

Adequacy of return

3) The Community

Economic and social stability

5) The Nation:

Security

Prosperity


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