Production Planning and Control Notes
Subject Overview
The fifth Operations Management group elective, covering PPC functions and forecasting, process planning and facility layout/
Subject at a glance
4
Units
28
Topics
4
Credits
4
Infographics
Unit-wise Syllabus
4 units — open any unit for detailed topic-wise notes, diagrams and important exam questions
- Objectives and functions of production planning and control
- types of production systems (job shop, batch, mass, continuous)
- aggregate production planning and Master Production Scheduling
- forecasting types
- techniques and forecast error
- 1
Demand forecast
- 2
Aggregate production plan
- 3
Master production schedule
- 4
MRP
Materials
- 5
Capacity requirements planning
- 6
Shop floor scheduling and control
Study guide
This unit covers PPC objectives and functions, production systems, aggregate planning, master production scheduling and forecasting. Prepare a simple aggregate plan.
- Product design analysis
- process sheet preparation
- line balancing
- advanced facility location methods (dimensional analysis, Brown and Gibson's method)
- types of layout
- rough-cut capacity planning and CRP
- work study
- method study
- work measurement and PMTS
Cycle time
Available time / required output
Minimum stations
Σ task times / cycle time (round up)
Line efficiency
Σ task times / (stations × cycle time) × 100
Balance delay
100 − efficiency
Study guide
You study product design analysis, process sheets, line balancing, advanced location methods, layouts, rough-cut capacity planning, CRP, work study and method study. Balance a simple assembly line.
- Routing procedure and route sheets
- bill of material
- scheduling policies and techniques (job shop, flow shop)
- dispatching procedures
- progress reporting and expediting
- correcting schedule deviations
- 1Routing
Decide the path and sequence
- 2Scheduling
Decide when each job runs
- 3Loading
Assign work to machines
- 4Dispatching
Release work orders
- 5Expediting
Follow up and fix delays
Study guide
You study routing, route sheets, bill of material, scheduling for job and flow shops, dispatching, progress reporting and expediting. Prepare a route sheet.
- Inventory functions and relevant costs
- ABC and VED analysis
- EOQ model
- P-System and Q-System inventory control
- introduction to MRP and ERP
- line of balance
- JIT inventory
- Kanban and lean manufacturing
Order when
Stock falls to the reorder point
At fixed time intervals
Order quantity
Fixed (EOQ)
Varies: up to a target level
Safety stock
Lower
Higher
Suits
Important A items
Many items from one supplier
Study guide
You study inventory functions and costs, ABC and VED, EOQ, P and Q systems, MRP, ERP, line of balance, JIT, Kanban and lean manufacturing. Compare P and Q inventory systems.
Why Production Planning and Control Matters
PPC ensures the right goods are made at the right time, and planning roles in manufacturing are among the most reliable operations careers.
How to Prepare for Production Planning and Control
- Practise line balancing, EOQ and scheduling problems.
- Visit a factory if possible.
- Learn MRP logic with a simple bill of materials.
Production Planning and Control: Frequently Asked Questions
What is MRP?
Material Requirements Planning calculates what materials are needed, in what quantity and when, from the production schedule and bills of materials.