Production Planning and control

Production Planning and control: 

Production Planning and control By Pavani Asst Prof GRCP, HYD

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Production is transformation of raw materials to finished goods Planning looks ahead, anticipates possible difficulties and decides in advance as to how the production, best, be carried out Control phase makes sure that the programmed production is constantly maintained

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Production operations should be effective and efficient –plan them properly Req – raw material, process, schedule etc 3 phases planning, action, control

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Batch : a specific quantity of a drug fomulation that is intended to have uniform character and quality within specified limits and is produced acc to a single mfg order during the same cycle of manufacture In process material- material fabricated, compounded, blended or derived by chemical reaction that is further used in the preparation of the drug product Lot : a batch or a specific identified portion of a batch having uniform character and quality within specified limits Lot number, control number, batch number Theoretical yield Practical yield

Production system: 

Production system Inputs Outputs Methods

Types of production systems: 

Types of production systems Continuous production : uninterrupted flow of material into methods and machines to produce standardized finished products in large quantities Materials are handled by fully automatic systems Known as flow production systems Form fill seal technology for the production of LVPs For mass production

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Form fill seal technology machines LVP’s

Intermittent production: 

Intermittent production Involves interrupted flow of material into methods and machines to produce standardized finished products in small quantities Pharmaceutical productions Batch production type Job order production type

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Flow sheet from cvs -69: 

Flow sheet from cvs -69

Flow sheet from khanna 7-2: 

Flow sheet from khanna 7-2

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Planning is deciding in advance what to do, how to do it, and who is to do it Planning is setting objectives, devising means to those ends, harnessing effort and systematically feeding back against expectations Prerequisite to other management functions Process of thinking before doing Anticipation of the future activities and determining the appropriate course of action to achieve a desired result

Information req: 

Information req Quality of products to be produced with specifications Quantity of products to be produced Sequence of operations Standard time for each operation Manufacturing capacities (availability of equipment, tools, packing and personnel) Standard time required for the completion of process Commencement of the operation

Procedure : 

Procedure

Routing : 

Routing Refers the path and optimum sequence of operations to be performed on the job Lays down the flow of work, i.e., what work is to be done and where and how it will be done, starting from raw material to the finished product Lists the sequence of operations and details such as flow of work in terms of sections, machines, persons

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Route sheets prepared and dispatched to production dept

Loading : 

Loading Defined as the relationship between load and capacity, so as to assign the work for the production Assignment of work to men , machines or department in advance without specifying when the work is to be done No of machines available, speeds and capabilities are considered Selection of substitute in case of breakdown is also a part of loading

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Tabulated list or chart showing the planned utilization of the machines or work stations in the plant Capacity: the time available for work at work centres expressed in machine hours or in man hours Load: to assign work to the capacity available at particular work centres

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Capacity -- The ability to perform appropriate tasks effectively, efficiently, and sustainably. Capacity Management is the process of reviewing and assessing your workcentres capability to produce your customer required products by ensuring that there is sufficient capacity to eliminate bottlenecks without generating large amounts of idle capability.

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To maintain uptodate picture of the availavble capacity in the plant Used for ensuring, Efficient utilization of plant and labour Setting a reliable delivery promises Forward planning of the purchases of new plant Prepared for each machine or group of machinery Shows productive capacity that is already occupied and at the same time the available production capacity

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Aims: To check the feasibility of production programmes To assist in efficient planning of new work To assist in balancing the plant to the existing load To assist in the fixing of reliable delivery promises

Production control: 

Production control Process of making sure that production is constantly maintained to produce the products of given specifications By – setting standards - measuring the job performing - getting feedback of results - taking corrective action For building quality products

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Importance: to check the production Follow up action Compares actual output with plan Points out deviations if any Functions: Receives work progress reports Compares them with the scheduled plans Removes causes of delay in production Modifies the schedules or plant capacities Expedites the work

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Progress control: Control group – to watch and record the progress of the operating facilities Progress report from production department Interprets and suggests Progress charts – for recording the work Compared against prescribed targets Draw the attention for the action or investigation

Progress report: 

Progress report Job identification Job order number Operation number Time of report Work completed reported depending on project duration – weekly,mnthly, yrly Written/oral/electronic system

Corrective action: 

Corrective action Depends on External factors: beyond the control of organization Internal factors: within the control of organization Flexible schedule: Capacity modification: Follow up or expediting: exception or feathering principle