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PRODUCTION,PLANNING,CONTROL & DOCUMENTATION

SEMINAR

SUBMITTED BY

K.ANIL KUMARReg.no-09

(M.pharm, IP)

UNDER THE GUIDANCE OF

Dr.BASU VENKATESWARA REDDYM.pharm Ph.D.

DEP. OF PHARMACEUTICS

St. Pauls College of Pharmacy

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TOPIC-Production,Planning,Control and Documentation.

CONTENTS:Production organisationObjectivesPoliciesGuide to pharmaceutical manufacture detailsTablets and Liquid oralsMaterials management Cost controls

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What do you mean by production?

Production in pharmaceutical industry mean that:

• Creation and maintenance of a clearly a defined organisation & makes it effective.

• It coordinates use of personal,land, building & equipment,including management of inventory assests.

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Production Planning and Control General Framework

Production Planning

Master Production Scheduling

Detailed Material Planning

Material and Capacity Plans

Purchasing

Demand Management

Resources Planning

Rough-cut Capacity Planning

Detailed Capacity Planning

Shop Floor Systems

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Production Planning and Control Organization

• It should be obvious that there is no single pattern for the organization of the production planning and control activity.

a) Planning Phaseb) Control Phase c) Centralized Production Planning and Controld) Decentralized Production Planning and Control

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Objectives of Production Planning Control

Manufacturing controls, is to contribute to the profits of the enterprise.

Customers satisfied through the meeting of delivery schedules.

To establish routes and schedules for work that will ensure the optimum utilization of materials, workers, and machines.

To provide the means for ensuring the operation of the plant in accordance with these plans.

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Production Planning and Control Functions

• The plan for the processing of materials through the plant is established by the functions of process planning, loading, and scheduling.

• The function of dispatching puts the plan into effect; that is, operations are started in accordance with the plant.

• Actual performance is then compared to the planned performance, and, when required, corrective action is taken.

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Some of the steps include like

Process planning(routing)Loading Scheduling Dispatching Combining functionsReporting or follow upRe-planningCorrective action

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• Type of Product. standard product involving only a few component parts, such as electric blankets, steam irons, or similar small appliances.

• Type of Manufacturing. This is probably the most influential factor in the control situation.

Factors Affecting Production Planning and Control

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production planning and control systems might be judged:

• 1. Inventory turnover• 2. Delivery lead time• 3. Percent of time meeting delivery promises• 4. Percent of orders requiring “splits” because of unavailable material.• 5. Number of expeditors• 6. Average unit cost.

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Manufacturing Facilities:

♦ Active Pharmaceutical Ingredients (APIs)– APIs are intended to furnish pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease or to affect the structure and function of the body.Chemical API Manufacturing:

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MATERIALS MANAGEMENT

• Material management is a scientific technique, concerned with Planning, Organizing &Control of flow of materials, from their initial purchase to destination.

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AIM OF MATERIAL MANAGEMENT:

To get

1. The Right quality

2. Right quantity of supplies

3. At the Right time

4. At the Right place

5. For the Right cost

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PURPOSE OF MATERIAL MANAGEMENT

• To gain economy in purchasing

• To satisfy the demand during period of replenishment

• To carry reserve stock to avoid stock out

• To stabilize fluctuations in consumption

• To provide reasonable level of client services

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Objective of material management

• Primary• Right price• High turnover• Low procurement • & storage cost• Continuity of supply• Consistency in quality• Good supplier relations• Development of personnel• Good information system

• Secondary• Forecasting• Inter-departmental harmony• Product improvement• Standardization• Make or buy decision• New materials & products• Favorable reciprocal

relationships

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Economy in material management

•Containing the costs

•Instilling efficiency in all activities

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Basic principles of material management 1.Effective management & supervision It depends on managerial functions of • Planning• Organizing• Staffing• Directing• Controlling • Reporting• Budgeting2.Sound purchasing methods3.Skillful & hard poised negotiations4.Effective purchase system5.Should be simple6.Must not increase other costs

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Elements of material management

1.Demand estimation

2.Identify the needed items

3.Calculate from the trends in Consumption during last 2 years.

4.Review with resource constraints

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Functional areas of material management

Purchasing

Central service supply

Central stores

The print shops

The pharmacy

Dietary

Linen services

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Materials Cost Control

Materials cost is one of the important elements of cost of product or unit.

It constitutes a substantial proportion of the total cost of production.For material cost control purposes, it is very essential to know about:

a) Material b) Material controlc) Material purchase control

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IT INCLUDES:

• Materials: The term 'materials' refers to all commodities or components which are consumed in the process of manufacture. The materials may be classified into Direct Materials and Indirect Materials.

• Direct Materials: Direct Materials form part of the finished products. They can be easily identified with a particular cost unit. For example, cotton used in textile mills, timber used in furniture industries.

• Indirect Materials : Indirect materials indirectly used for conversion from raw materials into finished products. They cannot be easily identified with a particular cost unit. For example, spare parts,

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MATERIALS COST CONTROL

• Materials are further classified on the basis of the nature which have to be used such as:

(a) Raw Materials, e.g., rubber, timber, steel etc. (b) Components, e.g., instruments (c) Consumable stores, e.g., cotton waste, brushes (d) Maintenance Materials, e.g., spare parts (e) Tools, e.g., jigs and fixtures

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CONCLUSION

• Finally it leads to useful of getting the right quality & quantity of supplies at right time,having good inventory control, adopting methods of condemnation,efficacy of products.

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BIBLIOGRAPHY

Industrial pharmacy 3rd edition by lachman, H.Lieberman.1Page no:-733-756Web source-article.com, slide share,pharma journels,pharma

bizz.com.Pharmaceutical production by C.V.S.Subrahmanyam,page no:-67-91.