1) State and explain the basic functions of PPC with the help of block diagram.

Block Diagram of PPC

The functions of Production Management depend upon the size of the firm. In small firms the production Manager may have to look after production planning and control along with Personnel, Marketing, Finance and Purchase functions. In medium sized firms, there may be separate managers for Personnel, marketing and Finance functions. But the production planning and control and Purchase and stores may be under the control of Production management department. In large sized firms the activities of Production Management is confined to the management of production activities only. As such, there are no hard and fast rules or guidelines to specify the function of Production Management, but in the academic interest we can mention some of the functions, which are looked after by the Production Management department. They are: 1) Materials The selection of materials for the product the Production manager must have sound Knowledge of materials and their properties, so that he can select appropriate materials for his product. Research on materials is necessary to find alternatives to satisfy the changing needs of the design in the product and availability of material resumes.

2) Methods Finding the best method for the process, to search for the methods to suit the available resources, identifying the sequence of process are some of the activities of Production Management. 3) Machines and Equipment Selection of suitable machinery for the process desired, designing the maintenance policy and design of layout of machines are taken care of by the Production Management department. 4) Estimating To fix up the Production targets and delivery dates and to keep the production costs at minimum, production management department does a thorough estimation of Production times and production costs. In competitive situation this will help the management to decide what should be done in arresting the costs at desired level. 5) Loading and Scheduling The Production Management department has to draw the time table for various production activities, specifying when to start and when to finish the process required. It also has to draw the timings of materials movement and plan the activities of manpower. The scheduling is to be done keeping in mind the loads on hand and capacities of facilities available. 6) Routing This is the most important function of Production Management department. The Routing consists of fixing the flow lines for various raw materials, components etc., from the stores to the packing of finished product, so that all concerned knows what exactly is happening on the shop floor. 7) Dispatching The Production Management department has to prepare various documents such as Job Cards, Route sheets, Move Cards, Inspection Cards for each and every component of the product. These are prepared in a set of five copies. These documents are to be released from Production Management department to give green signal for starting the production. The activities of the shop floor will follow the instructions given in these documents. Activity of releasing the document is known as dispatching. 8) Expediting or Follow up Once the documents are dispatched, the management wants to know whether the activities are being carried out as per the plans or not. Expediting engineers go round the production floor along with the plans, compare the actual with the plan and feed back the progress of the work to the management. This will help the management to evaluate the plans. 9) Inspection Here inspection is generally concerned with the inspection activities during production, but a separate quality control department does the quality inspection, which is not under the control of Production Management. This is true because, if the quality inspection is given to production Management, then there is a chance of qualifying the defective products also. For example Teaching and examining of students is given to the

same person, and then there is a possibility of passing all the students in the first grade. To avoid this situation an external person does correction of answer scripts, so that the quality of answers is correctly judged. 10) Evaluation The Production department must evaluate itself and its contribution in fulfilling the corporate objectives and the departmental objectives. This is necessary for setting up the standards for future. Whatever may be the size of the firm; Production management department alone must do Routing, Scheduling, Loading, Dispatching and expediting. This is because this department knows very well regarding materials, Methods, and available resources etc. In medium sized firms in addition to Routing, Scheduling and Loading, Dispatching and expediting, some more functions like Methods, Machines may be under the control of Production Management Department. In large firms, there will be Separate departments for Methods, Machines, Materials and others but routing, loading and scheduling are the sole functions of Production Management. 2) Objectives and benefits of implementing PPC concepts in enterprises I. Objectives of PPC

The objective of Production Planning and control is to produce the desired product or specified product by specified methods so that the optimal utilization of available resources is met with. Hence the production management is responsible to produce the desired product, which has marketability at the cheapest price by proper planning, the manpower, material and processes. Production management must see that it will deliver right goods of right quantity at right place and at right price. When the above objective is achieved, we say that we have effective Production Management system. Some of the main objectives To determine capacity of all manufacturing departments and to plan systematically coordinated and related production activities within the scope of the enterprise to meet sales requirements. To translate orders received from sales department into orders on the works department and to ensure steady plans of production activities. To find ways and means through which product manufacturing requirements such as materials and their necessary constituents such may be available in right quality and quantity at the right time. To coordinate a number of different department groups so that a fine balances of activities may be maintained. To promote fuller utilization of plants. To assist labor towards right and greater earnings. Staff in the effective performance of their duties.

Benefits Derived From Efficient Production Management The efficient Production Management will give benefits to the various sections of the society. They are: Consumer benefits from improved industrial Productivity, increased use value in the product. Products are available to him at right place, at right price, at right time, in desired quantity and of desired quality. Investors: They get increased security for their investments, adequate market returns, and creditability and good image in the society. Employee gets adequate Wages, Job security, improved working conditions and increased Personal and Job satisfaction. Suppliers: Will get confidence in management and their bills can be realized without any delay. Community: community enjoys Benefits from economic and social stability. The Nation will achieve prospects and security because of increased Productivity and healthy industrial atmosphere. 3) Case Study on Method Study Method Study on Whole-Life Cycle Automotive Manufacturing Industry CO2 Emission Accounting Method 1) Selection of work to be studied Nowadays automotive manufacturing industry, which belongs to traffic & transportation, has turned to be a large fuel consumer and an important source of air pollution. So how to calculate its carbon emission correctly and effectively has become a research focus. Record all the information Researches record the automotive carbon emissions mostly focus on GHGs emissions of automotive operation process in transportation department such as retained automotives in given regions of certain years of which the most popular ones are GREET model and MOBILE model and so on. GREET model assesses the energy utilization and emission influence during whole-life cycle of alternative fuels and advanced vehicle technologies. In terms of energy utilization, GREET model consists of three different levels: overall energy, fossil energy and petroleum based energy. While for emission influence, GREET model concludes three main GHGs (CO2 CH4 N2O) and five standard emissions (VOCCONOxPM10Sox).
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3) Examine the techniques Regional automotive manufacturing carbon emission calculation of whole-life cycle from raw material melting and producing to automotive manufacturing and finally to automotive operation and recycle process from the perspective of automobile manufacturers. These three processes take material structure, product structure and fuel structure of substance flow as main body of calculation. 4) Case analysis Here we take a case study to verify the regional automotive manufacturing industry whole-life cycle carbon emission calculating model). The case is about the CO2 emission of operation process of vehicles that are manufactured by Chongqing automotive manufacturers in year 2005. Our data sources include Chinas automotive industry yearbook, Chongqings governmental report and Chongqings environment bureau etc. The above case showed there are three main emitters during the operation process of automotives manufactured by Chongqings automotive and motorcycle industry in 2005: Mini cars, motorcycles and saloons which occupied respectively 36.3%, 18.8% and 15.0% of the total emission. While if we look at CO2 emission per vehicle, we can see that light diesel and heavy diesel vehicles emit much more CO2 than the other. 5) Develop and define a new model According to the national average, material producing process and automotive manufacturing process takes only 10 percent of the CO2 emission amount during the whole life cycle. Chongqings automotive and motorcycle industry is advanced compared with other regions in China, the CO2 emission of the former two processes can be estimated 8 percent. According to the above calculation, the CO2 emission of operation process is 1,848,200 tons, so that the whole-life cycle CO2 emission of Chongqings automotive and motorcycle industry is 1,996,100 tons. 6) Installing the above new method There is great significance to make clear of the whole-life cycle CO2 emission of automotive industry. Starting from the view of manufactures, regional automotive industry whole-life cycle GHGs emissions reflect the present situation of GHGs emissions more correctly, thus measure the contributions the regional automotive manufacturing industry made to reducing GHGs emissions globally. It also benefits the government of making GHGs emissions reducing policies and targets to build environmental friendly society as well as achieve economy growth.

4) Compare the industries which do you know that follows a mass production and other follows batch production. S.No 1. 2. 3. 4. 5. 6. PARTICULARS Name of the Industry Plant Layout Type of machine Type of Labor No. of products Product design BATCH PRODUCTION Chemical process industry Process Layout General purpose machine High skilled labor Less quantity Design changes on every lot Changes in machine As specification of each setup order changes the machines are to set according to the requirements of each order Investment on machine Less than the mass production Investment on inventories Here the operating cycle takes more time so inventory cost is more Material handling cost Material handling cost per product is high Size of orders Generally the size of orders is small and non repetitive in nature Production planning and The functions of routing, control scheduling and loading becomes relatively complicated due to odd size of order, nonrepetitive nature of the order, different delivery dates, etc., Examples sports shoes, pharmaceutical ingredients, inks, paints & adhesives, furniture, books and newspapers etc., MASS PRODUCTION Automobile industry Product Layout Special purpose machine Less skilled labor More quantity No changes in product design The setup of machine remains unchanged for a longer period Very high Less Material handling cost per product is less Generally the size of orders is large and repetitive in nature The functions of routing, scheduling and loading becomes relatively easy because repetitive orders.

7. 8. 9. 10. 11.

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Pulp and paper, cement, Manufacture of complex fertilizers, automobile parts and Petrol Pumps. Manufacture of glass by continuous automatic or semi automatic process.

NAME ROLLNO CLASS SUBJECT

: G.KRISHNAKUMAR : 08MER050 : FINAL YEAR B.E-MECHANICAL-A : PRODUCTION PLANNING AND CONTROL ASSIGNMENT-I