PPC 2marks

IE 8693 / Production Planning and Control Mechanical Engineering 2023-2024
IE8693 PRODUCTION PLANNING AND CONTROL LTPC

3 00 3
OBJECTIVE: To understand the various components and functions of production planning and control
such as work study, product planning, process planning, production scheduling, Inventory Control. To
know the recent trends like manufacturing requirement Planning (MRP II) and Enterprise Resource
Planning (ERP).
UNIT I INTRODUCTION 9
Objectives and benefits of planning and control-Functions of production control-Types of production-job-
batch and continuous-Product development and design-Marketing aspect - Functional aspects-Operational
aspect-Durability and dependability aspect aesthetic aspect. Profit consideration-Standardization,
Simplification & specialization Break even analysis-Economics of a new design.
UNIT II WORK STUDY 9
Method study, basic procedure-Selection-Recording of process - Critical analysis, Development -
Implementation - Micro motion and memo motion study - work measurement - Techniques of work
measurement - Time study - Production study - Work sampling - Synthesis from standard data -
Predetermined motion time standards.
UNIT III PRODUCT PLANNING AND PROCESS PLANNING 9
Product planning-Extending the original product information-Value analysis-Problems in lack of product
planning-Process planning and routing-Pre requisite information needed for process planning-Steps in
process planning-Quantity determination in batch production-Machine capacity, balancing-Analysis of
process capabilities in a multi product system.
UNIT IV PRODUCTION SCHEDULING 9
Production Control Systems-Loading and scheduling-Master Scheduling-Scheduling rules-Gantt charts-
Perpetual loading-Basic scheduling problems - Line of balance - Flow production scheduling-Batch
production scheduling-Product sequencing - Production Control systems-Periodic batch control-Material
requirement planning kanban –Dispatching-Progress reporting and expediting-Manufacturing lead time-
Techniques for aligning completion times and due dates.
UNIT V INVENTORY CONTROL AND RECENT TRENDS IN PPC 9
Inventory control-Purpose of holding stock-Effect of demand on inventories-Ordering procedures. Two
bin system -Ordering cycle system-Determination of Economic order quantity and economic lot size-
ABC analysis-Recorder procedure-Introduction to computer integrated production planning systems-
elements of JUST IN TIME SYSTEMS-Fundamentals of MRP II and ERP.
TOTAL: 45 PERIODS
TEXT BOOK:
1. Martand Telsang, “Industrial Engineering and Production Management”, S. Chand and Company,
First edition, 2000.
2. James.B.Dilworth,”Operations management – Design, Planning and Control for manufacturing and
services” Mcgraw Hill International edition1992.
REFERENCES:
1. Samson Eilon, “Elements of production planning and control”, Universal Book Corpn.1984
2. Elwood S.Buffa, and Rakesh K.Sarin, “Modern Production / Operations Management”, 8th Ed. John
Wiley and Sons, 2000.
3. Kanishka Bedi, “ Production and Operations management”, Oxford university press, 2nd Edition 2007.
4. Melynk, Denzler, “ Operations management – A value driven approach” Irwin Mcgrawhill. 5. Norman
Gaither, G. Frazier, “ Operations management” Thomson learning 9th edition IE, 2007
5. K.C.Jain & L.N. Aggarwal, “Production Planning Control and Industrial Management”, Khanna
Publishers, 1990.
6. S.N.Chary, “Theory and Problems in Production & Operations Management”, Tata McGraw Hill,
1995.
7. Upendra Kachru, “ Production and operations management – Text and cases” Excel books 1st edition
2007.
St. Joseph’s College of Engineering 1

COURSE OUTCOMES:
On completion of this course student will be able;
C411.1 Know the function of production planning and control
C411.2 Understand the various methodologies in work study and motion study.
C411.3 Understand the functions of product planning, process planning.
C411.4 Understand the process of production scheduling and production control systems
Know the recent trends like Inventory Control, manufacturing requirement Planning (MRP
C411.5
II) and Enterprise Resource Planning (ERP).
Relationship of Course Outcomes to Program Outcomes/ Program Specific Outcomes

PO PSO
COs PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
C411.1 3 2 - 3 - - - - - - 3 3 3 2
C411.2 3 - - - - - - - - - 3 3 3 2
C411.3 3 - - - - - - - - - 3 3 3 2
C411.4 3 2 - 3 2 - - - - - 3 3 3 2
C411.5 3 2 - 3 2 - - - - - 3 3 3 2
1: Slight (Low) 2: Moderate (Medium) 3: Substantial (High) 4: „ - „ No correlation
RELATION BETWEEN COURSE CONTENT WITH COs

UNIT-1 - INTRODUCTION OF PRODUCTION PLANNING AND CONTROL
Knowledge Course
S.No Topics
level Outcomes
Production Planning and control-objective, Types, benefits
1. Ap,An,U
and functions
2. Ap,An,U Product Development and design C411.1
3. Ap,An,U Profit consideration
4. An,U Break Even Analysis
UNIT – II WORK STUDY
Knowledge Course
S.No Topics
level Outcomes
1. An,U,C Method Study
2. An,U,C Time study
3. An,U,AP Measurement Techniques
C411.2
4. Ap,An,U Micromotion study
5. An,U,Ap Work Sampling
6. Ap,An,U Predetermined Motion time study

UNIT – III PRODUCT PLANNING AND PROCESS PLANNING

Knowledge Course
S.No Topics
level Outcomes
1. Ap,An,U,C Product Planning
2. U,An,C Value Analysis
3. Ap,An Process Planning and Routing
C411.3
4. Ap,An Batch production
5. Ap,An Process capability
6. Ap,An Multi Product system
UNIT – IV PRODUCTION SCHEDULING

Knowledge Course
S.No Topics
level Outcomes
1. U,Ap Production control Systems
2. U,Ap,C Loading and Scheduling
C411.4
3. U,Ap,An,C MRP
4. U,Ap,An,C Kanban
UNIT – V INVENTORY CONTROL AND RECENT TRENDS IN PPC

Knowledge Course
S.No Topics
level Outcomes
1. U,An Inventory control
2. U,An,Ap Two Bin system
3. U,An,Ap EOQ C411.5
4. U,An,Ap ABC analysis
5. U,An,Ap MRP II and ERP
Ap – Apply; An – Analyze; U – Understand, E- Evaluate,C-Create

UNIT-1 - INTRODUCTION OF PRODUCTION PLANNING AND
CONTROL
PART-A-C411.1
1) Define production planning and control (April 2017/2018)
PPC may be defined as the direction and coordination of the organizations materials and physical
facilities towards the attainment of pre-specified goals in the most efficient way.
2) Define production planning
Production planning is defined as the determination, acquisition and arrangement of all facilities
necessary for future production of products.
3) What is meant by production control?
Production control through control mechanism, tries to take corrective action to match the plant
and actual production .Thus production control reviews the progress of the work and takes
corrective steps in order to ensure that programmed production takes place.
4) What are the Phases of PPC?(April 2018, Nov 2018, April 2022)
PPC involves three phases
1. Pre-planning phase, 2. Planning phase, 3. Control phase
5)List the various functions/activities of PPC? (May 2017, May 2023)
2. Materials planning
3. Facility planning
4. Methods planning
5. Estimating
6. Process planning (routing)
7. Scheduling and loading
8. Dispatching
9. Expediting (or follow up)
10. Inspection and testing
11. Evaluation
6) Differentiate between routing and scheduling
Routing provides the best and the most economical production sequence, whereas scheduling
prepares a logical time- table showing the starting and finishing time of each production work in
accordance with some predetermined program. In simple words routing considers the „where‟
aspects and scheduling „when‟ aspects.
7) What is Production system?
A production system is the frame work within which the conversion of inputs into output occurs.
At the one end of the production system are the inputs and at the other end outputs.
8) How can you classify the production system?
a. Job shop production
b. Batch production
c. Mass production
d. Process or continuous production
9) What do you mean by batch production?
In batch production, the products are made in small batches and in large variety. Each batch
contains identical items but every batch is different from others.
10) Differentiate between intermittent and continuous production systems.
The job shop production and batch production are also known as intermittent production systems.

The mass production and process production are termed as continuous production system.
11) What types of plant layouts are suitable for job shop, batch and continuous
production?
1. Job shop production – Process of functional layout
2. Batch production - Cellular layout
3. Continuous production – Line or product layout
12) What is the objective of product analysis?
The main objective of product analysis is to obtain qualitative as well as quantitative evaluation
of the influencing factors which determine primarily the success of a manufactured product.
13) Distinguish the terms durability and dependability.
Durability refers to the length of the active life or endurance of the product under given working
conditions.
Dependability refers to the reliability with which the product serves its intended function.
14) What do you mean by design manufacture and design for assembly?
Design for manufacture (DFM) means the design for ease of manufacture of the components of a
product. Design for assembly (DFA) means the design of the product for ease of assembly.
15) What do you understand by product standardization? (Nov 2018)
Standardization means setting up standards or measuring sticks by which extent, quality,
quantity, value, performance, or service may be gauged or determined.
16) What are the 3S‟s with respect to product development techniques?
1. Standardization 2. Simplification 3. Specialization
17) What do you mean by specialization?
Specialization is the process whereby particular firms concentrate on the manufacture of a limited
number of products or types of products.
18) What are the advantages of specialization?
a. Better utilization of equipment
b. Higher productivity
c. Greater efficiency
d. Better quality
e. Reduced production cost & hence lower unit price, and
f. Use of standardized methods.
19) What do you understand by break-even analysis? (April 2017, April 2019, April
2022, May 2023)
Break-even analysis, also known as cost-volume-profit analysis, is the study of inter-
relationships among a firm‟s sales, costs and operating profit at various levels of output.
The break-even point is the point at which revenue is exactly equal to costs. At this point, no
profit is made and no losses are incurred. The break-even point can be expressed in terms of unit
sales or dollar sales.

20) Contrast product simplification with product diversification.
Product simplification is the process of reducing the variety of products manufactured i.e.,
variety reduction. Product diversification is completely opposite to simplification. Product
diversification involves adding new products or lines products to achieve a balanced product
range.
21) List the Objectives of Planning and Control (April 2019)
Production planning is an activity that is performed before the actual production process takes
place. It involves determining the schedule of production, sequence of operations, economic
batch quantities, and also the dispatching priorities for sequencing of jobs. Production control is
mainly involved in implementing production schedules and is the corollary to short-term
production planning or scheduling.
22) Enumerate the functions of production control. (April/May 2021)
Production control is the task of predicting, planning and scheduling work, taking into account
manpower, materials availability and other capacity restrictions, and cost so as to achieve proper
quality and quantity at the time it is needed and then following up the schedule to see that the
plan is carried out, using whatever systems have proven satisfactory for the purpose.
23) Indicate the significance of product development. (April/May 2021)
Product planning and development facilitate the profitability and growth of business.
Development of new products enables a business to face competitive pressures and to diversity
risks. Product is the most important constituent of marketing mix.
24)What is a Job shop production?
A job shop is a type of manufacturing process structure where small batches of a variety of
custom products are made. In the job shop process flow, most of the products produced require a
unique set-up and sequencing of processing steps.
25)Give some examples for Job shop production.
Examples of a job shop include a machine tool shop, a factory machining center, paint shops, a
French restaurant, a commercial printing shop, and other manufacturers that make custom
products in small lot sizes. Volume and standardization is low and products are often one of a
kind.
PART-B-C411.1
1. Explain the objectives and benefits of planning and control.
2. Discuss the functions of production planning and control.(April 2019, April 2022, May 2023)
3. Briefly explain the types of production system: (Nov 2018)
4. Discuss the various key aspects of Product Design and Development in detail. (April 2017, April
2019, April 2022)
5. Describe the Factors influencing product design:
6. Describe Standardization. (Nov 2018)(April 2021)
7. Write a note on Simplification. (Nov 2018) (April 2021)
8. Briefly discuss about Specialization: (Nov 2018) (April 2021)
9. What is Break Even analysis: Describe it.(April 2021)
10. Write a note on Economics of new design. (April 2021)
11. Explain the characteristics features of (i) Batch Production and (ii) Mass Production (iii)
Continuous Production (April 2017, April 2021, May 2023)
12. Why it is necessary to analyze the product. Explain the various analysis that are carried
out? (April 2017)
13. A manufacturer sells an item for Rs.13 per unit. He incurs a fixed cost of Rs.60, 000 and
Variable cost of Rs.8 unit. Find the break even production quantity and also the number of units
to be produced to get a profit of Rs.12, 000.
Part- C-C411.1
1. What are the assumptions made in break-even analysis? An example of a analysis company
reveals the following information.
Variabl
Cost Element Fixed cost
e
cost
Direct material 32.8 -
Direct labor 28.4 -
Factory overheads 12.6 1,89,900
Distribution overheads 4.1 58,400
General administration overheads 1.1 66,700
Budgeted sales 18,50,000
Determine break even sales volume. The profit at the budgeted sales volume. The profit if the
actual sales drop by 10%. The profit if the actual sales increase by 5% for budgeted sales.
2. Compare the various types of productions.(April 2018)
3. Discuss the recent trends in PPC.(April 2018)
4. You own a factory and make steel furniture as and when orders received from the customer
describe the procedure you could follow for planning and control of production in your
factory. (April 2019).
UNIT-2 WORK STUDY

PART-A-C411.2
1)Define Work Study(April 2017, May 2023)
Work study is a generic term for those techniques, particularly method study and work
measurement, which are used in the examination of human work in all its contexts and which
leads systematically to the investigation of all factors which after the efficiency and economy of
the situation being reviewed, in order to effect improvement.
2) List the objective of work study. (April 2018)
1. To find the most economical way of doing the work
2. To simplify and standardize the methods, materials, tools and equipment.
3. To determine the time required by a qualified worker to perform the work at a normal pace.
4. To plan the training program for the workers for the new methods.
3) Define method study. ( Nov 2018, April 2019, April 2022)
Method study is the systematic recording and critical examination of existing and proposed ways
of doing work, as a means of developing and applying easier and more effective methods and
reducing costs.
4) List the objectives of method study.
a. To improve the processes and procedures.
b. To improve the design of plant and equipment
c. To improve the plant layout.
d. To improve the use of men, materials and machines.
e. To achieve efficient material handling.
f. To improve the flow of production and processes.

5) Differentiate between operation and inspection.
An operation always takes the material, component or service a stage further towards completion.
An inspection does not take the material any nearer to become a completed product.
It merely verifies that an operation has been carried out correctly as to quality and / or quantity.
6) Differentiate between „Permanent storage‟ and „Delay‟.
The difference is that a requisition, chit, or other form of formal authorization is generally
required to get an article out of permanent storage but not out of temporary storage.
7) What is a process chart? Mention its types
A process chart is a graphical representation of the sequence of events and related information
that occur in the work method or procedures. There various types of process charts are
Outline process chart, Flow process chart, Two- handed process chart
8) Differentiate between outline process chart and flow process chart. (Nov 2018)
An outline process chart is a process chart given an overall picture by recording in sequences only
the main operations and inspections. A flow process chart is a graphical representation of all
operations, transportations, inspections, delays and storages occurring during a process or
procedure.
9) Distinguish between flow diagram and string diagram.
The sting diagram must be drawn correctly to scale. The flow diagram can be drawn
approximately to scale. The flow diagram would look cumbersome when there are too many to
and fro movement between points but, such movements will not affect the string diagram.
10) Define time study. (April 2017)
Time study is defined as a work measurement technique for recording the times and rates of
working for the elements of a specified conditions and for analyzing the data so as to obtain the
time necessary for carrying out the job at a defined level of performance.
11). Why the job is divided into elements?
i) To ensure that productive work is separated from unproductive activity.
ii) To ensure better and accurate performance rating.
iii) To identify and distinguish different types of elements.
iv) To facilitate checking of method.
12) What is meant by performance rating?
Performance rating is the process of adjusting the actual pace of working of an operator by
comparing it with the mental picture of pace of an operator working at normal speed.
13) List the various allowances to be considered while calculating the standard time of
job.
i) Relaxation allowances
ii) Contingency allowances
iii) Process allowances
iv) Interference allowances
v) Special allowances
14) Define the terms basic time and standard time.
Basic time may be defined as the time for carrying out an element of work standard rating.
Standard time is the time allowed to an operator to carry out the specified task under specified
conditions and defined level of performances.
15) What is meant by work sampling?( May 2023)
Work sampling is defined as a method of finding the percentage occurrence of a certain activity
by statistical sampling and random observations.
16) What do you mean by synthetic data?
Synthetic data is the data derived from the analysis of the accumulated work measurement data in
the form of tables and formulas where the data is arranged in a form suitable for building up the
standard times and similarly machine processing times by synthesis.
17) What is PMTS? (April 2019)
PMTS stands for Predetermined Motion Time System. A predetermined motion time system
consists of a set of time data which has been developed from many observations of a worker‟s
performance.
18) Give the acronym for the following: MTA, WFS and MTM.
MTA - Methods Time Analysis, WFS – Work Force System, MTM – Method Time
Measurements
19) Define time study.
Time study is defined as a work measurement technique for recording the times and rates of
working for the elements of a specified conditions and for analyzing the data so as to obtain the
time necessary for carrying out the job at a defined level of performance.
20) Define Cumulative timing.
The cumulative timing allows the stopwatch to start at the entire duration of the study.
Accumulated elemental times are recorded in sequence while the watch is running. At the end of
the study, the time for each element is determined by subtracting the beginning time from the end
time.
21)What are THERBLIGS? Give any four with symbols. (April 2014)
THERBLIG‟s are the basic building blocks of virtually all manual work performed at a single
workplace and consisting primarily of hand motions. Frank Gilbreth was the first to catalog (list)
the basic motion elements.
Symbols of any two THERBLIG‟s - G – Grasp , A- Assemble , Select, Find ,
I - Inspect , Search .
22)List the steps involved in Time study. (April 2014)
● SELECT(Job to be timed )
● OBTAIN & RECORD(Details regarding method, operator, job & working
condition)
● DEFINE(the elements, break the job into element convenient for timing)
● MEASURE ( time duration for each element and assets the rating
● EXTEND(Observed time into normal time[basic time])
● DETERMINE(Relaxation and Personal Allowances)
● COMPUTE(Standard time for the operation for defined job or operation)
23) What are the advantages of SIMO chart?
Simultaneous motion Cycle Chart – (i) The principles behind the multiple activity chart and the
two handed process chart are combined in SIMO chart, (ii) It is drawn on a time based scale, due
to that which allows the job designer to see the relative time taken by each part of the job.
24) Mention the tools used in time study. (April 2022)
Stop watch Study, Work Sampling etc.
25) Write a note on micro motion study. (April/May 2021)

Micro motion study is one of the most accurate techniques of work analysis used for work
improvement. It makes use of motion pictures of the different activities or movement, so with the

help of camera. Very small time upto 0.0005 minute can be measured and recorded by this
system.
26) Indicate the significance of work measurement. (April/May 2021)
Work measurement is very important for promoting productivity of an organization. It enables
management to compare alternate methods and also to do initial staffing. Work measurement
provides basis for proper planning. Since it is concerned with the measurement of time it is also
called 'Time Study'.
PART-B-C411.2
1. Describe about Method study and its procedure and objectives in detail. (April 2017, 2018, 2019,
April 2022, May 2023)
2. Write a note on Recording techniques in method study. (April 2021)
3. Describe about Micro motion and Memo motion study. (April 2017) (Nov 2018)
4. Write a note about Work measurement techniques. (April 2017, April 2019, April 2021, April
2022, May 2023)
5. Describe about Time study and production study. (April 2017) (Nov 2018)
6. Write a note on Synthesis method.
7. Discuss about Predetermined Motion Time System (PMTS). (Nov 2018) (April 2021)
8. Explain the steps involved in work study. (Nov 2018)
9. Briefly discuss the steps in work sampling study. (April 2017) (Nov 2018)
10. Explain the Stop watch time study
11. Explain in detail about Effective “Therblings” with suitable examples.
12. The elemental times for 4 cycles of an operation using a stop watch are presented below:
Calculate the standard time for the operation if
(i) Elements 2 and 4 are machine elements (ii) For other elements, the operator is rated at 110%
(iii) Total allowances are 15% of the normal time. (May 2023)
Element Cycle time in minutes
s
1 1.5 1.5 1.3 1.4
2 2.6 2.7 2.4 2.6
3 3.3 3.2 3.4 3.4
4 1.2 1.2 1.1 1.2
5 0.51 0.51 0.52 0.49
Part -C-C411.2
1. A work sampling study was concluded to establish the standard time for an operation. The
observation of the study conducted are given below: (April 2016)
(1) Total number of observations : 160

(2) Manual (hand controlled) work : 14
(3) Machine controlled work : 106
(4) Machine idle time : 40
(5) Average performance rating : 80%
(6) Number of parts produced : 36
(7) Allowance for personal needs and : 10%
fatigue
(8) Study conducted needs :3
days
(9) Available working hours/day : 8 hrs
2. How the standard time for a simple manual job is made up? Explain the various allowances
used to build the standard time.
3. Explain multiple activity chart with an example. (April 2018)
UNIT – 3 PRODUCT PLANNING AND PROCESS

PLANNING PART-A-C411.3
1) What is product planning?
i) The evaluation of the range, mix, specification and pricing of existing and new products in
relation to present and future market requirements and competition.
ii) Planning of product range, mix, specification and pricing to satisfy company object
iii) Specifying the research, design and development support required.
2) What is the purpose of feasibility study in relation to product planning? (April 2017)
The purpose of feasibility study is to extend the market analysis with the intent of arriving at a
preferred system configuration that the firm is willing to offer the product or product-mix in
response to an identified need.
3) List the information that can be obtained from the system operation concept.
i) Identification of prime mission of the system
ii) Definition of operating characteristics of the system
iii) Anticipated usage of the system and its elements iv).Identification of effectiveness factors
4) List the information that can be obtained from the system maintenance concept.
i) Identification of level of maintenance support.
ii) Definition of repair policies
iii) Definition of effectiveness measures
iv). Establishment of supportability requirements in system/ equipment design
v) Establishment of requirements of logistics support
5) List the activities of advanced product planning.
i) Product selection and justification ii) Products specifications and plans
iii) Product acquisition plan, iv) Product evaluation plan
6) What is value analysis? (April 2018, April 2022)
Value analysis is a disciplined approach that ensures the necessary functions at minimum cost
without comprising on quality, reliability, performance and appearance.
7) What is value? List its types. (April 2018)
Value, in general, taking the „use value‟ as an objective, is the ratio between the function and the
cost. Value=Types of economic value: 1. Use value, 2. Esteem value, 3. Cost value, 4.Exchange
value.
8) How can you increase the value of a product?
The value of a product can be increased:
i) By reducing the costs ii) By improving function
iii) By increasing function by increasing the costs disproportionately low
9) Differentiate between primary and secondary functions with respect to value analysis.
Primary functions are the basic functions which the product is specially designed to perform.
Secondary functions are those which if deleted would not prevent the devices from performing
its primary functions
10) Distinguished between value analysis an value engineering.
Value analysis is the application of a set of techniques to an existing product with a view to
improve its value. Thus value analysis is a remedial process.
Value engineering is the application of exactly same set of techniques to a new product at the
design stage itself. Therefore value engineering is a preventive process.
11) Mention any four uses of value analysis. (April 2017, May 2023)
i) It reduces the cost of product and determines the appropriate cost for the liable
performance of the product.
ii) It helps employees to understand their jobs in a better fashion
iii) It creates new ideas and concepts for R&D department
iv) It creates cost consciousness among the employees in the firm
12) When do you apply value analysis?
Value analysis can be applied in case of the following indications.
i) When the firm is unable to meet delivery schedules
ii) Due to change in technology
iii) When the cost of manufacturing is high
iv) When rate of profit has a falling trend
13) List any four reasons for product‟s unnecessary costs.
i) Failure to utilize specialized knowledge
ii) Poor design of the component
iii) Lack of ideas and relevant information
iv) Unavoidable delivery constraints
14) List the various phases of value analysis.
i) Orientation phase ii) Information phase iii) Functional analysis iv) Creative phase
v) Evaluation phase
15) What is meant by process planning?
Process planning can be defined as “an act of preparing a detailed processing documentation for
the manufacture of a piece part or assembly”.
16)List the various information required for process planning. (April 2017)
1) Assembly and component drawings and bill of materials
2) Machine and equipment details
3) Standard time for each operation and details of set up time for each job
4) Availability of machines, equipment and tools
17) What are the factors affecting production planning? (Nov 2018)
i. Non-availability of materials
ii. Plant, equipment and machine breakdown
iii. Changes in demand and rush orders.
iv. Absenteeism of workers.
v. Lack of coordination and communication between various functional areas of
business.
18) What is meant by machine balancing?
Machine balancing refers to the procedure of adjusting the times at work centers to conform as
much as possible to the required cycle time.
19) List the commonly used methods to reduce the cycle time to a minimum.
i) Reduce/eliminate idle time in the bottleneck activity
ii) Reduce the independent activity time iii) Reduce the concurrent activity time.
20) What is meant by machine loading? (April 2019)
Machine loading is the process of assigning specific jobs to machines, men or work centers based
on relative priorities and capacity utilization.

21) State the major objective of assembly line balancing.
It is to subdivide the network into several sub networks (stations) without violating the
precedence relationships and allocating operations to each station without exceeding the cycle
time. i.e the sum of the times of operations allocated to each station should not exceed the cycle
time.
22) What are the considerations in selection of an equipment or process?
Consideration in selection of an equipment or process -Economic considerations, production rate
and unit cost of production, Durability and dependability, lower process rejection, minimum
setups and put away times, longer productive life of machine or equipment and functional
versatility.
23) What are the various process planning activities? (April 2018, April 2022)
The major process planning activities are interpretation of product design data, selection of
machining processes, determination of datum surfaces, selection of the required jigs and fixtures,
accessories, sequencing of operations, determination of production tolerances, determination of
the cutting condition parameters, estimation of production times and generation of CNC
machines programming data.
24) State the main functions of process planning.(Nov/Dec 2018)
„Make or buy‟ decision is the main function of process planning. Here decision is made about
which parts are to made in the factory and which parts are to be bought from outside. Decision on
whether to make or buy is taken by break even analysis.
25) Mention the importance of product planning. (April/May 2021)
For efficient, effective and economical operation in a manufacturing unit of an organization, it is
essential to integrate the production planning and control system. An efficient system of
production planning and control helps in providing better and more economic goods to customers
at lower investment.
26) Write a note on quantity determination in batch production. (April/May 2021)
In inventory management, Economic Batch Quantity (EBQ), also known as Optimum Batch
Quantity (OBQ) is a measure used to determine the quantity of units that can be produced at the
minimum average costs in a given batch or product run
.
PART-B- C411.3
1. Discuss about Product planning. (April 2017)
2. Explain the steps in Value Analysis / Engineering . (Nov 2018) (April 2019, May 2023)
3. Discuss in detail about Process planning and Routing. (April 2017)
4. Write a note on Prerequisite information for process planning
5. What are the Steps in process planning? Explain in detail. (April 2017, April 2022)
6. Describe in detail about Quantity determination in batch production problems. (April 2017)
7. What is Machine capacity, balancing? (Nov 2018)
8. A gear Manufacturer has gear shaper and gear hobbers. The gear can be processed on gear
shaper as well as gear hobber. The following information is given. Which of the two machines
will you choose to do the job if the order quantity if (i) 1000 numbers and order is unlikely to
repeat (ii) 1000 numbers and the order is likely to repeat for 3 years? (April 2022)
Gear Gear
Shaper Hobber
Machine time per piece (min) 12 4
Machine cost per hour (Rs.) 45 120

Set up time (min) 60 90
Tooling up cost (Rs.) 400 2000
9. Explain the steps involved in: i) Product planning ii) Process planning .(April 2019)
10. Define routing. What are its economic advantages? How route cards are prepared and what
are their uses?
11. Describe the problems due to the lack of Product Planning.
12. Explain how process capabilities are analyzed in a multi product system. (April 2017)(April
2021, May 2023)
13. Define process planning and explain the various factors considered for selecting a
process and equipment.
14. Explain the significance of value analysis and discuss on its phases. (April 2021)
Part - C C411.3
1. Define value analysis and present a FAST Diagram for a PEN.
2. Explain the phrase “Extending the original product information” with suitable examples. (April
2017)
3. State the ten commandants of value analysis. (April 2018)
4. Explain the responsibilities of a process planning engineer. (April 2018)
UNIT – 4 PRODUCTIONSCHEDULING
PART- A-C411.4
1. What do you mean by loading?
Loading may be defined as the assignment of work to a facility without specifying when the work
is done and in what sequence.
2. What is scheduling? What are its objectives? (April 2018, May 2023)
Scheduling refers to the setting of operation start dates so that jobs will be completely by their
due date. The objectives of production scheduling are:
i) To meet due date ii) To minimize lead time iii) To minimize setup time or cost
iv) To minimize work-in process inventory v) To maximize machine or labor utilization
3. What is master scheduling? (April 2017) (April 2019)
The master schedule, also known as master production schedule (MPS), formalize the production
plan and translates it into specific end-item requirements over a short to immediate planning
horizon.
4. What is MPS?
The master schedule, also known as master production schedule (MPS), formalize the production
plan and translates it into specific end-item requirements over a short to immediate planning
horizon.
5. What are Gantt charts?
Gantt charts are usual aids used to depict the sequencing, load on facilities, or progress associated
with work effort over a well-defined time period.
6. What is priority sequencing?
Priority sequencing is a systematic procedure for assigning priorities to waiting jobs thereby
determining the sequence in which the jobs will be performed.
7. What are the dispatching rules?
Dispatching rules, also known as priority rules or sequencing rules or scheduling rules, are the
rules used in obtaining a job sequence.
8. What is meant by product sequencing?
Priority sequencing is a systematic procedure for assigning priorities to waiting jobs thereby
determining the sequence in which the jobs will be performed.
9. What is meant by EBQ scheduling?( April 2022)
EBQ scheduling is nothing is nothing but the economic batch quantity scheduling that can be
performed by using aggregate run-out method.
10. What do you mean by line-of-balance? What are its uses?( April 2022)
Line-of-balance is a charting technique that uses lead times and assembling sequencing to
compare planned component completion with actual component completions.
11. List the various charts that are used in line-of-balance analysis.
1. Operation program chart/ or assembly chart, 2. Objective chart 3. Progress chart
4. Line of balance chart
12. What is the use of objective chart?
The objective chart shows the contrast between expected completion schedules of production and
the actual performance.
13. When do you use progress chart?
The progress chart is a bar type chart which shows the actual number of items produced at each
operation stage against the quantities that should have been produced as indicated by line of
balance.
14. What is MRP?
Materials requirements planning (MRP) is a computational technique that converts the master
schedule for final products into a detailed schedule for the raw materials and parts used in the
final products.
15.List the various inputs required for MRP .
1. Master production schedule 2. Bill of materials file 3. Inventory record file
16. What is MPS?
Master Production Schedule (MPS) is a detailed plan that shows how many end items will be
available for sale or distribution during specific periods.
17. List some commonly used forms in dispatching.
1. Material requisitions 2. Job cards/ Tickets 3. Labour cards/Tickets 4. Move cards/Tickets
5. Inspection cards/Tickets 6. Tool and gauge tickets
18. What do you mean by expediting?
Expediting, also known as follow-up or progressing, is a control function that keeps track of the
„progresses of work in accordance with planned schedule.
19. List the various recording methods for the progressing purpose.
1. Gantt charts
2. Visual charts
3. Cumulative and weekly charts

20. What is meant by Line Efficiency and Balance Delay.
Line Efficiency – It is the ratio of Total station time to the product of Cycle time and no of work
station. Balance Delay – It is the percentage of total idle time on the line to total time spent by the
product from the beginning to end of line.BD = number of work station X Cycle time –
21. What is meant by Gantt Chart and how it is constructed?

Gantt chart is a principal tool used for both loading and scheduling. It consists of a simple
rectangular grid, divided by series of parallel horizontal and vertical lines. Vertical lines divide
the chart into units of time. The scale units can be year months weeks or days or hours according
to the duty for which chart is required. The horizontal lines divide the chart into sections, which
can be used to represent either work status tasks or work centers. The four jobs which are to be
processed on three work centers are shown.
22. State the steps in Johnson‟s algorithm for solving sequencing problems of n jobs and
3 or 4 machines. (April 2018)
The N jobs can be sequenced in M machines by the following steps
1.The M machine problem is first converted in to the two machine problem by either of the
following conditions
Minimum of M1 ≥ Maximum of (M2, M3 … Mm-1)
(Minimum of Mm ≥ Maximum of (M2, M3 … Mm-1) Or both hold.
2. The required sequence is then obtained by applying the time deviation method as done in two
machine problem.
23. What are the different techniques of loading and scheduling? (Nov 2018)
a. Master scheduling b. Perpetual loading c. Order scheduling d. Loading by schedule period
24. Define dispatching. (Nov 2018, May 2023)
It is the routine of setting productive activities in motion through the release of orders and
instructions in accordance with previously planned times and sequences embodied in route sheets
and schedule charts.
25. List any five priority sequencing rules. (April 2019, May 2023)
1. First come, first served (FCFS)
2. Shortest processing time (SPT)
3. Earlier due date (EDD)
4. Critical Ratio (CR)
26. Define Manufacturing Lead Time. (April/May 2021)
Production lead time (or manufacturing lead time) is the period of time between vendor's
purchase order being placed and the manufacturer completing the order. A short production lead
time is better than a long production lead time, as it ensures customers get products quickly.
PART-B-C411.4
1. What is Batch production scheduling? Explain it.
2. What are the Scheduling techniques: Explain. (April 2017) (Nov 2018)
3. Explain the Sequencing rules.(April 2021, April 2022)
4. Describe the Material Requirement Planning (MRP or MRP-I): (April 2017)
5. An assembly line is to be designed to operate 7.5 hours per day and supply a steady demand of
300 units per day. The following table shows the tasks and their performance times. (i) Draw the
precedence diagram. (ii) What is the cycle time (iii) Assign tasks to work stations stating your
logical rules (iv) What is the efficiency of your line balance? (April 2014, April 2022)
Tasks a b c d e f g h i j k l
Precedence
- - - a b c d e f g h,i j
tasks
Performanc
e 70 40 45 10 30 20 60 50 15 25 20 25
time
6. There are seven jobs which are to be processed first on Machine 1 and then on Machine II.
Process time in hours is given below. Find the optimal sequence and total elapsed time. (April
2014)
Job a b c d e f G
Machine I 6 24 30 12 20 22 18
Machine 16 20 20 13 24 2 6
II
7. Briefly explain the various techniques used for loading and scheduling.
8. (i) Briefly explain the five main stages of line of balance technique.(April 2021)
(ii) Explain different techniques employed for aligning completion times and due dates.
9. Explain the significance of scheduling. What are the types of scheduling?(April 2022)
10. Explain the following (i) GANTT Chart construction (ii) MRP.(April 2021, May 2023)
11. Explain the Period Batch Control, Flow Production Scheduling .
12. Sequence the following jobs to minimize the processing times on the two machines. Also
compute the idle times of the machines.(April 2022, May 2023)
Job 1 2 3 4 5 6
Machine 1 5 9 4 7 8 6
Machine 2 7 4 8 3 9 5
13. What is progressing? Explain its function. Also write short notes about “recording progresses‟
(Nov 2018)
14. Discuss in detail about the various factors that affect scheduling. (April 2019)
15. What is meant by the dispatching? Enumerate and list the various functions of dispatching.
.Explain the various document raised by dispatcher. (April 2019)
16.Describe the Flow production scheduling and mention its applications.(April 2021)
Part -C-C411.4
1. A small scale unit manufactures a product and it is expected to apply with week 1, 120 in
week 4, 120 in week 6, 100 in week 8. Each product is made of 2 housings, a shaft assembly and
one wheel. For these components order quantities, lead times and inventories on hand at the
beginning of period as given below.
Part Order Lead Inventory on

quantity time head
Housings 600 2 weeks 200
Shaft 400 3 weeks 440
assembly
Wheel 800 1 week 100
Apart from the above requirement, another 180 shaft assembly is required for another customer
600 units of housing are already scheduled to be received as beginning of week 2. Complete the
material requirement plan for housing shaft and wheel. Show that quantities of order must be
released and when they must be released in order to satisfy the MPS.

2. Four items A,B,C,D are to be processed successively in batches on the same facility. The
demand and production rates, set up costs and holding costs for each product are given below:
Demand Production Holding cost/ Set Up cost

Item per rates per
Unit/ Annum
Year per Year batch
A 10000 250 0.05 100
B 5000 100 0.05 50
C 8000 200 0.10 80
D 12000 300 0.05 60
Determine the No. of cycles per annum and the quantity in batches and the production times for
each items in a cycle. Assume 250 working days in a year.
3. Explain the various charts used in LOB. (April 2018)
UNIT-5 INVENTORY CONTROL AND RECENT TRENDS IN PPC

PART -A-C411.5
1. Define term inventory and inventory control.
An inventory is a stock of an item or idle resource held for future use. Inventory control may be
defined as the Scientific method of determining what to order , when to order and how much to
order and how much to stock so that the costs associated with buying and storing are optimal
without interrupting production and sales.
2. Mention at least four reasons for keeping an inventory. (April 2019)
1. To maintain independence of operations.
2. To meet variation in product demand.
3. To allow flexibility in production scheduling.
4. To provide a safeguard for variation in raw material delivery time.
3. Define the following terms: (a) Lead time (b) Re-order point
(a) Lead time: The time gap between placing of an order and its actual arrival in the inventory is
known as a lead time.
(b) Re-order point: The level of inventory at which an order is placed is known as Re-order
point or re- orders level.
4. Define the terms buffer stock, and re-order quantity.( April 2022)
Safety or buffer stock: This represents the minimum stock which must be maintained at all times.
If stock is less than the buffer stock, then the work will stop due to shortage of materials.
Re-order quantity: The quantity of items to be ordered at re-orders level is known as re-order
quantity.
5. What is EOQ?( May 2023)
The technique of economic ordering quantity (EOQ) strikes a balance between the ordering cost
and the carrying cost. EOQ is the size of order which minimizes the total cost of carrying inventory
and ordering.
6. What is JIT? List its Benefits (April 2011, April 2022)
Just-In-Time is a management that strives to eliminate sources of manufacturing waste by
producing the right part in the right place at the right time.
■ Reduction in inventories
■ Improved quality
■ Reduced space requirements
■ Shorter lead times

7. What are the objectives of JIT? (April 2011)
The JIT is applied to achieve the following goals:
■ Lower production costs
■ Increased productivity
■ Increased machine utilization
■ Greater flexibility
1. Zero defects
2. Zero setup time
3. Zero inventories
4. Zero handling
5. Zero breakdowns
6. Zero lead time and
8. List the seven wastes that becomes the target of elimination in a JIT process
1. Waste of overproduction, 2. Waste of waiting, 3. Waste of transportation, 4. Waste of
processing itself 5. Waste of stocks, 6. Waste of motion, 7. Waste of making defective products
9. What do you mean by kanban production control system? Brief about Kanban.
Kanban means sign or instruction card in Japanese. A kanban is a card that is attached to a
storage and transport container. It identifies the part number and container capacity, along
with other information.
10. Differentiate between Pull system and Push system
A kanban system, is a Pull system, in which the Kanban is used to Pull parts to the next production
state when they are needed i.e., in Pull system product is made to order.
A MRP system is a Push system in which a detail production scheduled for each part is used to
Push the parts to the next production stage when scheduled i.e., in a Push system the product is
made to stock.
11. What is MRP II?(April 2019, May 2023)
MRP II is defined as a computer base system for planning scheduling and controlling the materials,
resources and supporting activities needed to meet the Master Production Schedule. In fact MRP II
consist of virtually functions in a PPC system plus additional business functions that are related to
production.
12. What are the functions of MRP II?
1. Management planning: Business strategy aggregate production planning, maser production
scheduling, rough cut capacity planning and Budget planning.
2. Customer services: Sales forecasting, order entry, sales analysis and finished goods inventory
3. Operations planning: Purchase order and work order release
4. Operations execution: Purchasing, product scheduling and control, work in-process, inventory
control shop floor control and labor hour tracking
5. Financial function: Cost accounts receivable, accounts payable, general ledger and payroll.
13. Define the terms inventory and inventory control?
An inventory is a stock of an item or idle resource held for future use. Inventory control may be
defined as the scientific method of determining what to order, when to order and how much to order
and how much to stock so that costs associated with buying and storing are optimal without
interrupting production and sales.
14. Differentiate between anticipation and fluctuation inventories.
Anticipation inventories: these are stocks maintained to meet the anticipated i.e., expected demand.

Fluctuation inventories: these are safety stocks maintained to meet the unexpected demand and
thereby to Avoid the risk of losing sales.
15. What are inventory costs?
(i) Ordering costs ii) Carrying costs iii) Shortage costs iv) Purchase cost
16. What do you mean by inventory carrying costs?
Inventory carrying costs are the costs associated with holding a given level of inventory on hand.
The holding costs include: i) Costs for storage facilities ii) Handling costs iii) Depreciation, taxes
and insurance iv).Costs on record keeping
17. What is EOQ? (April/May 2017
The technique of economic ordering quantity (EOQ) strikes a balance between the ordering cost
and the carrying cost. EOQ is that size of order which minimizes the total costs of carrying
inventory and ordering.
18. What is two bin system? List its advantages. (May 2017)
A two-bin system is a type of fixed-order system in which inventory is carried in two bins. A
replenishment quantity is ordered when the first bin is empty. During the replenishment lead time,
material is used from the second bin. A two-bin system is mostly used in assembly environments.
The advantage of a two-bin system is a minimal chance of a stock-out and the ease to handle.
Inventory control method (used usually for small or low value items) in which when the first
bin is used up, an order is made out for replenishment. The second bin contains enough quantity
of the item to last until the ordered quantity arrives
19.State the elements of JIT? (April/May 2017)
Basic elements of JIT - Flexible resources - Cellular layouts -Pull production system - Kanban
production control - Small-lot production - Quick setups - Uniform production levels - Quality at
the source - Total productive maintenance - Supplier networks
20. State the classification of inventory. (April/May 2017) (Nov 2018)
In most of the organizations inventory is categorized according to ABC Classification Method,
which is based on pareto principle. Here the inventory is classified based on the value of the units.
The principle applied here is based on 80/20 principles.
21. List the “seven wastes” that becomes the target of elimination in a JIT process.
i) Waste of over production
ii) Waste of waiting
iii) Waste of transportation
vi) Waste of motion
vii) Waste of making defective products
22. Define ERP. (April/May 2017)
Enterprise resource planning (ERP) is the integrated management of core business processes, often
in real-time and mediated by software and technology. These business activities can include:
product planning, purchase, Production planning, Manufacturing or service delivery.
23. State the advantages of ABC analysis. (April 2018)
(i) It ensures control over the costly items in which a large amount of capital is invested.
(ii) It helps in developing scientific method of controlling inventories. Clerical costs are
considerably reduced and stock is maintained at optimum level.
(iii) It helps in maintaining stock turnover rate at comparatively higher level through scientific
control of inventories.

(iv) It ensures considerable reduction in the storage expenses. It results in stock carrying stock.
(v) It helps in maintaining enough safety stock for C category of items.
24. What is order cycle? (Nov/Dec 2018)

The time period between two successive orders is called order cycle .When orders are placed at
equal time intervals it is known as fixed order interval system (Or) cycle review system.
25. Mention the significance of Inventory control. (April/May 2021)
Inventory control helps connect the upstream activities of purchasing and manufacturing to the
downstream activities of sales and product demand to prevent bottlenecks, speed up processes,
identify slow-moving or obsolete items, and even help evaluate suppliers.
26. Write a brief note on computer integrated production planning systems. (April/May
2021) Computer integrated production planning system is the technique of using computers to
control an entire production process. It‟s commonly used by factories to automate functions such
as analysis, cost accounting, design, distribution, inventory control, planning and purchasing.
These functions are often linked to a central, computer-controlled station to enable efficient
materials handling and management, while delivering direct control and monitoring of all
operations simultaneously. Essentially, every individual piece of a manufacturing process
including engineering, production and marketing is organized.
PART-B-C411.5
1. What is Inventory Control? Explain them. (Nov 2018)
2. What are the Effects of demand on inventories?
3. Explain the Ordering procedure in detail. (April 2021)
4. Write a note on ERP.(April 2019).
5. A manufacturer has to supply his customers 3600 units of his product per year. Shortages are
not permitted. Inventory carrying cost amounts Rs.1.2 per unit per annum. The set up cost per
run is Rs.80. Find (i) Economic order quantity (ii) Optimum number of orders per annum (iii)
Average annual inventory cost (iv) Optimum period of supply per optimum order.
6. Explain briefly the procedure for ABC analysis and list its merits and demerits. (April
2019)(April 2021)
7. Alpha industry estimates that it will sell 12,000 units of its products for the forthcoming year.
The ordering cost is Rs. 100 per order and the carrying cost per unit per year is 20 percent of the
purchase price per unit. The purchase price per unit is Rs. 50. Find (i) Economic order quantity
(EOQ) (ii) No. of orders per year (iii) Time between successive orders.
8. Compare P and Q systems of inventory replenishments with their merits and demerits (Nov.
2010)
9. The annual demand of a product is 48000 units. The average leads time is 4 weeks. The
standard deviation of demand during the average lead time is 75 units/ week. The cost of
ordering is Rs.400 per order. The cost of purchase of the product per unit is Rs.10. The cost of
carrying per unit per year is 15% of the purchase price. The maximum delay in lead time is 2
weeks and the probability of this delay is
0.25. Assume a service level of 0.95. (a) If Q system is followed, find the reorder level. (b) If the
P system is followed, find the maximum inventory level.
10. Describe the elements of JIT System and Kanban system? (April 2021, May 2023)
11. Perform ABC analysis on the items given below and classify them based on ABC analysis.

Item 101 102 103 104 105 106 017 108 109 110
Annual
Consumption 200 100 2,000 400 6,000 1,200 120 2,000 1,000 80
(Units)
Unit Cost 40 360 0.20 20 0.04 0.8 100 0.70 1 400
(Rs.)
12 Determine the optimal order quantity of an inventory item with the following data, Annual
demand = 2,800 units, Unit cost = Rs.5, Ordering cost = Rs.36/order, Carrying cost = 20% of
unit cost. (April/May 2017, April 2022)
Order Quantity <50 500≤Q<125 ≥1250
0 0
Discount % on unit
Nil 4% 8%
cost
13. Following components are required for repairing oil engines. Classify the same by ABC analysis
(April 2017, May 2023)
Component
C01 C02 C03 C04 C05 C06 C07 C08 C09 C10
Code
Unit
100 200 50 300 500 3000 1000 7000 5000 60
Cost(Rs)
Annual
Consumptio 100 300 700 400 1000 30 100 500 105 100
n (units) 0
14. Discuss in detail about MRP-II and ERP. (April 2021, April 2022)
15. What is meant by Two Bin inventory control system? (April 2019)(April 2021)
Part -C-C411.5
1. Explain the purpose of maintaining inventory in any production unit. (April/May 2017) (April
2018)
2. Explain ABC analysis and its significance in the inventory control with suitable examples.
(April/May 2017) (Nov 2018, May 2023)
3. Explain the costs associated with inventory. (April 2018) (April 2019)
4. How minimum cost batch size is determined. (April 2018)
5. Explain the implementation procedure of ERP in an Automobile auxiliary unit. (Nov 2018)
6. Write detailed notes on computer integrated production & control systems. (April 2022)

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IE 8693 / Production Planning and Control Mechanical Engineering 2023-2024

IE8693 PRODUCTION PLANNING AND CONTROL LTPC

St. Joseph’s College of Engineering 1

Relationship of Course Outcomes to Program Outcomes/ Program Specific Outcomes

RELATION BETWEEN COURSE CONTENT WITH COs

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UNIT – III PRODUCT PLANNING AND PROCESS PLANNING

UNIT – IV PRODUCTION SCHEDULING

UNIT – V INVENTORY CONTROL AND RECENT TRENDS IN PPC

Ap – Apply; An – Analyze; U – Understand, E- Evaluate,C-Create

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UNIT-2 WORK STUDY

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25) Write a note on micro motion study. (April/May 2021)

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(1) Total number of observations : 160

UNIT – 3 PRODUCT PLANNING AND PROCESS

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21. What is meant by Gantt Chart and how it is constructed?

Part Order Lead Inventory on

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Demand Production Holding cost/ Set Up cost

UNIT-5 INVENTORY CONTROL AND RECENT TRENDS IN PPC

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24. What is order cycle? (Nov/Dec 2018)

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