List the objectives of planning and control.

• To ensure efficient utilization of production facilities.

• To coordinate the production activities of different departments.
• To maintain adequate but not excessive stock of raw materials, work in progress and of
finished goods to meet production requirements and delivery schedules at the most
economical level.
• To ensure production of right product in right quality at the right time.

What is meant by simplification?

Simplification as the elimination of super focus varieties, sizes, dimensions etc .,
simplification makes the product, assembly or design simpler, less complex or less difficult.

What are therbligs?

• Therbligs are 18 kinds of elemental motions used in the study of motion economy in the
workplace.

What is Simo chart?

A basic motion-time chart used to show the simultaneous nature of motions

What are the factors affecting product planning?

Market need
Product life cycle
Differentiation of product
Customer needs
Promotional needs
Technology

What is machine capacity?

Machine capacity capacity is the maximum amount of work that a machine is capable of completing in a
given period. Machine (hr) capacity of a machine is totally related with number working hours per day
and non-available time.

What are the main objectives of loading?

To assist in balancing the plant resources
To assist in fixing of reliable delivery promises
To check the feasibility of production need arise from customer order or market trend
To assist in the efficient planning of new work order
List the key functions of the production scheduling and control.

List the advantages of two-bin system.

The benefit of two bin system is preventing running out of stock. The empty working bin triggered for
replenishment. Hence, reserve bin can be replaced during the lead-time period to meet the demand of the
customers. Besides, minimize the risk is one of the advantage using two bin system.
What is MRP-II SYSTEM?
Manufacturing Resource Planning (MRP II) evolved from early Materials Requirement Planning
(MRP) systems by including the integration of additional data, such as employee and financial needs. The
system is designed to centralize, integrate and process information for effective decision making in
scheduling, design engineering, inventory management and cost control in manufacturing.
Part-B

11. (a) Describe the functions of production control.

Planning phase
-Prior Planning
• Fore-casting
– Estimation of future activities
– establishment of future requirements of men, machine, material, money, and
time
• Order writing
– Providing authority to peoples to do a particular job
• Product design
– Collect the information necessary to describe the work in detail
– Drawings, bill-of-materials, specification
- Action planning
• Process planning: The determination of most economical method of performing an
activity all factors being considered.
• Routing- The arrangement of work stations is determined by the route.
• Material control: Determination of material requirements and control of material
(Inventory Control).
• Tool Control : Tool control may be sub divided into two categories
– Design and procurement of new tools.
 – Control storage and maintenance of tools after procurement.
• Loading: Determination and control of equipment and man power requirements.
Loading may be defined as the assignment of work to be facility. The facility may be
equipment, manpower or both.
• Scheduling: Determination when the work is to be done. Scheduling consists of time
phasing of loading (Work load) i.e., setting both, starting and ending time for the
work to be done.
• The common practice dictates that routing, loading and scheduling be performed
simultaneously.
Action Phase

• The work is started in the action phase.

• Dispatching- only one production planning activity
• Dispatching is the transition from the planning phase to action phase.
• It consists of actual release of detailed work authorization to the work centers.
Follow up or Control phase
-Progress reporting
• Once the work is started in an activity it is necessary to evaluate continuously the
progress in terms of plan so that deviations can be detected and corrected as quick as
possible. The control phase accordingly consists of two parts:
• Progress reporting: (Data collection). The first step in progress reporting is to
collect data for what is actually happening in the activity (Progress of work)
• Data interpretation: After the data has been collected, then it is necessary to
interpret it by comparing the actual performance against the plan.
-Corrective action
• Expediting
– If the data collected from the production unit indicates that there is significant
deviation from the plan and the plan cannot be changed, then some action
must be taken to get back on plan.
• Re-planning
– It should be emphasized that the plan is not to be changed but to be followed,
however, if after expediting to correct deviation it is found that, it is
impossible to perform according to plan. It would be necessary to re plan the
whole affair. It may also be found that there were errors made while
developing the original plan. In all such cases re-planning is necessary.

11.(b) (i) Discuss the functional aspects of product development

 Functional aspect affects the design of a product, its complexity, its aesthetic and its price
 Clearly defined objective; Eg. Washing machine: to wash cloth
 Functional scope: what to be covered and what not are covered; washing machine:
heating, extra rinse, tub cleaning, etc,.
 Functional modularity – a scope for customer’s choice as add-on function steaming unit
in an iron-box; Fruit mixer: Variety of Jars and containers, a power unit, regulator,
interface to support all attachment
 Versatility-Eg
 Functional range and their combination as product variations eg mobile phones
 Method of doing each function

(ii) Explain the economics of a new design.

12. (a) (i) Describe the basic procedure of method study.
Selection uses three factors: economical factor, Human Factors, technology factors
Based on the economical factors, generally the following jobs are selected.
1. Operations having bottlenecks (which holds up other production activities).
2. Operations done repetitively.
3. Operations having a great amount of manual work.
 4. Operations where materials are moved for a long distance.
Record
All the details about the existing method are recorded. This is done by directly observing the
work. Symbols are used to represent the activities like operation, inspection, transport, storage
and delay. Different charts and diagrams are used in recording.
2. They are:
1. Operation process chart: All the operations and inspections are recorded.
2. Flow process chart
3. Two-handed process chart: Motions of both lands of worker are Right hand-Left hand chart
recorded independently.
4. Multiple activity chart: Activities of a group of workers doing a single job or the activities of a
single worker operating a number of machines are recorded.
5. Flow diagram: This is drawn to suitable scale. Path of flow of material in the shop is recorded.
6. String diagram: The movements of workers are recorded using a string in a diagram drawn to
scale.
Examine
The individual activity is examined by putting a number of questions.
• The following factors are questioned
1. Purpose – To eliminate the activity, if possible.
2. Place – To combine or re-arrange the activities.
3. Sequence – -do-
4. Person – -do-
5. Means – To simplify the activity.
develop
The answer to the questions given below will result in the development of a better method.
1. Purpose – What should be done?
2. Place – Where should it be done?
3. Sequence – When should it be done?
4. Person – Who should do it?
5. Means – How should it be done?
Define
(b) Brief description of the new method.
(c) Reasons for change.
(d) Advantages and limitations of the new method.
(e) Savings expected in material, labour and overheads.
(f) Tools and equipment required for the new method.
Install
Install stage consists of
(a) Gaining acceptance of the change by supervisor.
(b) Getting approval of management.
(c) Gaining the acceptance of change by workers and trade unions.
(d) Giving training to operators in the new method.
(e) To be in close contact with the progress of the job until it is satisfactorily executed.
Maintain
Periodical review is made. The reactions and suggestions from workers and supervisors are
noted. This may lead to further improvement.
 (ii) What is production study? Explain.
Production study: A continuous study of relatively lengthy duration often made with the object
of checking an existing or proposed standard time or its constituent parts, or obtaining
information concerning the rate of output.
• Before work values can be used, it is essential to carry out production studies to ensure
that the calculations (Work Measurement) have been correctly made and that the people
working to the values can achieve a reasonable performance.
• Assessments of utilisation of equipment or employees may be made using work
sampling (activity sampling). A technique in which a large number of observations are
made over a period of time of one group of machines, processes or workers. Each
observation records what is happening at that instant and the percentage of observations
recorded for a particular activity or delay is a measure of the percentage of time during
which that activity or delay occurs.
• It is normally used for collecting information on the percentages of time spent on
activities, without the need to devote the time that would otherwise be required for any
continuous observation.
Work sampling or activity sampling (surveys) produce acceptable results; the accuracy may be
predetermined and selected by the practitioner before the study begins. Under certain
circumstances it is necessary to obtain a detailed account of a complete period of work such as a
shift or day, from which data may be extracted for checking and audit purposes.
• A continuous study used for this purpose is known as a production study.
• The minimum length of a production study is half a day or half a shift, and the details,
results and conclusion should be filed with the set-up.

12. (b) Write short note on

(i) Synthetic data
Synthetic data is "any production data applicable to a given situation that are not obtained by
direct measurement"
Synthesis is a work measurement technique for building up the time for a job at a defined level
of performance by totaling element times obtained previously from time studies on other jobs
containing the elements concerned, or from synthetic data.
Synthetic data is the name given to tables and formulae derived from the analysis of accumulated
work measurement data, arranged in a form suitable for building up standard times, machine
process times, etc. by synthesis.
Synthetic times are increasingly being used as a substitute for individual time studies in the case
of jobs made up of elements which have recurred a sufficient number of times in jobs previously
studied to make it possible to compile accurate representative times for them.
Standard Data for Work Measurement
(1) Constant elements which do not vary from job to job.
(2) Elements, similar in nature, but varying due to difficulty, size, pressure and weight
etc. involved.
(3) Elements, which vary in the time of performance because of the variation in the
technical characteristics of materials or processes such as speed, depth, feed of cut etc.
The elemental breakdown can be microscopic or macroscopic according to the situation.
 Microscopic data is based upon minute movements (i.e. Therbligs-reach, carry, hold etc.)
involved in the operation and is complied by microscopic methods. In macroscopic
methods, data deals with big elements. Hence this group of motions as the elements such
as pick up the component and fix in chuck etc. Macro data is collected by time study and
the micro data is the result of micro motion study and analysis.
The various steps involved in developing the standard data are as follows:
1. Fix the range of applicability of standard data.
2. Job is broken down into elements. Elements are the constant elements or variable
elements or machine element.
3. Conduct the time studies for variety of jobs under different conditions.
4. Making a check list of job conditions and verifying the job conditions against the job
conditions mentioned in the data.
5. Summarize the time studies using a summary form.
6. Constant and variable elements are differentiated.
7. Job characteristics are analyzed which leads to variability in elements.
8. A plot can be made between the normal time of each element and the variable
dimension e.g………. size of the item as shown in Fig.

9. Standard Data is compiled.

10. Finally, the data is tested for its accuracy and correctness.

(ii) PMTS
• Predetermined motion time system (PMTS) is a work measurement technique whereby times
established for basic human motions are used to build up the time for a job at a defined level of
performance.
• PMTS also called predetermined time system (PTS), is a database of basic motion elements
and their associated normal time values, together with a set of procedures for applying the data to
analyze manual tasks and establish standard times for the tasks.
• The PMTS database is most readily conceptualized as a set of tables listing time values that
correspond to the basic motion elements, the lowest level in our hierarchy of manual work
activity
They include motions such as reach, grasp, move, and release.
Advantages
 Does not disrupt the actual production operation.
 No performance ratings are necessary.
 No allowance factors are necessary.
 Unions tend to accept it as fair.
 Particularly effective in firms that employ many workers performing similar tasks, i.e.
 it is cost-effective.
  Can be used for planning purposes because the time standard can be set before the job actually
exists.

13. (a) Explain the steps involved in product planning ?

13. (b) Write short notes on quantity determination in batch production with suitable example?
14. (a) Discuss in detail about the various factors that affect scheduling. Explain any one
technique used in loading and scheduling process.
Internal factors
 Stock of finished goods kept by company.
 Process intervals of each product.
 Type of machines available.
 Availability of personnel.
 Availability of materials.
 Manufacturing facilities available in the company.
 Economic production runs (EPR) or optimum lot size.
External factors
 Due date
 Demand
 Dealer inventory
14. (b) What are the components of Material Requirement Planning (MRP)?

 Master Production Schedule (MPS): MPS is designed to meet the market demand (both the firm orders and forecasted
demand) in future in the taken planning horizon. MPS mainly depicts the detailed delivery schedule of the end products.
However, orders for replacement components can also be included in it to make it more comprehensive.
  Bill of Materials (BOM) File: BOM represents the product structure. It encompasses information about all sub
components needed, their quantity, and their sequence of buildup in the end product. Information about the work centers
performing buildup operations is also included in it.
 Inventory Status File: Inventory status file keeps an up-to-date record of each item in the inventory. Information such as,
item identification number, quantity on hand, safety stock level, quantity already allocated and the procurement lead time
of each item is recorded in this file.
 Routing File: This file specifies the sequence of operations required to manufacture components, sub-assemblies and
finished goods.
 Master Parts File: It contains information about production time of sub-assemblies and components produced internally
and lead time for externally procured items.

After getting input from these sources, MRP logic processes the available information and gives information about the following:

 Planned Orders Receipts: This is the order quantity of an item that is planned to be ordered so that it is received at the
beginning of the period under consideration to meet the net requirements of that period. This order has not yet been
placed and will be placed in future.
 Planned Order Release: This is the order quantity of an item that is planned to be ordered in the planned time period for
this order that will ensure that the item is received when needed. Planned order release is determined by offsetting the
planned order receipt by procurement lead time of that item.
 Order Rescheduling: This highlight the need of any expediting, de-expediting, and cancellation of open orders etc. in
case of unexpected situations.

15. (a) Write short notes on computer aided Production Planning and Control
Key features of CAPPC are
 Engineering and manufacturing database
 Material requirements planning
 Capacity planning
 Inventory management
 Shop floor control
 Cost planning and control
 Comprises all the information needed to fabricate the components and assemble the
products.

Engineering and manufacturing database includes

Item master file

Bill of material file

Routing file

Work center file

Tool file

MRP

A closed loop MRP is followed in that purchase and production activities control modules
interfaced with MRP-module.

Dynamic updating of order status done by purchasing interface generates updated order
status from which new planned order releases.
Shop floor interface updates MRP production status by collecting daily production and
operator time-sheet data.

Once an MRP system is in place, inventory data can be augmented by other useful information

Labor hours

Material costs

Capital costs

Virtually any resource

Then the system is called MRP II or Manufacturing Resource Planning. An extension of the
MRP system to tie in customers and suppliers

1. Allows automation and integration of many business processes

2. Shares common data bases and business practices

3. Produces information in real time

 Coordinates business from supplier evaluation to customer invoicing

3. capacity planning

Concerned with determining the labor and equipment resources needed to meet the production
schedule.

Capacity planning for short term include decisions on

employment levels

number of work shifts

overtime or reduced workweek

inventory stockpiling

order backlogs

subcontracting

4. Inventory management

The inventory management module of the CIPMS should accomplish two major functions.

 Inventory accounting
  Inventory accounting is concerned with inventory transactions and inventory
records. Inventory transactions include receipts, issues, returns & loans

 Inventory planning and control

Many of the planning and control activities are accomplished by the MRP module.
Other functions include

• Determining economic lot sizes

• Determining safety stock levels

• Determining reorder points

• ABC inventory analysis

• Analysis of usage rates for lot size calculations

• Automatic generation of purchase requests

5. Shop floor control is concerned with monitoring the progress of orders in the factory and
reporting the status of each order to management so that effective control can be exercised. The
functions of a shop floor control system are

 Priority control and assignment of shop orders

 Maintain information on WIP for MRP
  Monitor shop order status information
 Provide production output data for capacity control

Cost control
It estimates what is the Expected cost? Collect the information of actual coat incurred and then
find the difference and why difference.

It receives data from all other CIPMS modules and reduces them to a lowest common
denominator : money.

Input source Input

Bill of materials Components & materials used

Process route sheets Manufacturing operations employed

Time standards Operation times

Labor & machine rates Associated cost

Material quotations Material cost

Accounting data Overhead rates

15. (b) Explain the main functions and methodology adopted in implementing ERP.
• ERP is the next evolution of the MRP system.
• It attempts to integrate the information flow from all departments of the company:
finance, marketing, production, logistics and human resources.
• A properly set up ERP system allows all departments to intercommunicate and monitor a
customer order at any point in time.

Module Function
Sales and This module records sales orders and scheduled deliveries. Information
Distribution (SD) about the customer including pricing, address and shipping instructions,
billing details, etc., is maintained and accessed from this module.
Materials This module manages the purchasing of raw materials from suppliers and
Management the subsequent handling of raw materials inventory, from storage to work-
(MM) in-progress goods to shipping of finished goods to the customer.
Production This module maintains production information. This module facilitates to
Planning (PP) create production plans and schedule productions, and record information
on actual production activities.
Plant This module helps to manage maintenance resources and facilitates
Maintenance planning for preventive maintenance of plant machinery in order to
(PM) minimize equipment breakdowns.
Asset This module helps the company to manage fixed-assets including plant and
Management machinery and their related depreciation.
(AM)
Human Resources This module facilitates employee recruiting, hiring, and training. This
(HR) module also includes payroll and benefits of employees.
Project System This module facilitates the planning and control of research and
(PS) development, construction, and marketing projects.
Financial This module records transactions in the general ledger accounts. This
Accounting (FI) module generates financial statements for external reporting purposes.
Workflow (WF) This module includes set of tools that can be used to automate any of the
activities in ERP system
Controlling (CO) This module serves internal management purposes, assigning
manufacturing costs to products and to cost centers so the profitability of
the company’s activities can be analyzed. The CO module supports
managerial decision making.
16. (a) A gear manufacturer has gear shaper and gear hobbers.
The gear can be processed on gear shaper as well as gear hobber. The following is given. Which of the two
machines will you choose to do the job if the order quantity is
(i) 1000 numbers and order is unlikely to repeat
(ii) 1000 numbers and the order is likely to repeat for 3 years?
 Cost parameters Gear shaper Gear hobber
Machine time
12 04
per piece (min)
Machine cost
45 120
per hour
Set up time
60 90
(min)
Tooling up
400 200
cost (Rs)

16. (b) Explain the procedural steps involved in the work sampling study and illustrate how work
sampling is used for the computation of standard time for an operation which involves both
manual and machine elements.