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11Sep

What are the Steps in Production Planning and Control?

Production planning and control is a predetermined process that plans, manages and controls the allocation of human resource, raw material, and machinery to achieve maximum efficiency.

Production planning is a sequence of steps that empower manufacturers to work smarter and optimize their production process in the best possible manner. This helps manufacturers work smarter by efficiently managing internal resources to meet customer demand.

Objectives of Production Planning and Control (PPC)

Having a reliable Production Planning and Control software in your company makes it easy to:

  • Ensure cost-efficient production process
  • Promote timely delivery of goods
  • Minimize production time
  • Improve customer satisfaction
  • Coordinate with departments about production, to ensure things are on the same page
  • Ensure the right man is assigned the right work

Production planning is the core of any manufacturing unit. It includes material forecasting, master production scheduling, long term planning, demand management and more. The PPC process kicks off with demand forecasting of a product, and thereafter designing the production plan according to the demand to move it forward.

Production planning is a strategy to plan a chain of operations that supports manufacturers to be at the right place, at the right time so that they can achieve the maximum efficiency from their resources.

Now, let’s straightway talk about the steps involved in Production Planning and Control. As per the British Standards Institute, there are four stages or essential elements in the process of production planning and control. These are as follows:

1. Routing
Routing determines the path from which the raw materials flow within the factory. Once, the sequence is followed, raw materials are transformed into finished goods.

Setting up time for every step is important to measure the overall duration of the production process. Simply saying, routing in manufacturing states the sequence of work and operations. Routing throws light on the quantity and quality of materials to be used, resources involved (men, machine, and material), the series of operations and place of production.

Routing manages “How”, “What”, “How much”, & “Where” to produce in a manufacturing company. It systematizes the process and nurtures optimum utilization of resources to get the best results.

2. Scheduling
Scheduling is the second step that emphasizes on “When” the operation will be completed. It aims to make the most of the time given for completion of the operation.

As per Kimball and Kimball, scheduling is defined as –

“The determination of the time that should be required to perform the entire series as routed, making allowance for all factors concerned.”

Organizations use different types of schedules to manage the time element. These include Master Schedule, Operation Schedule, Daily Schedule and more.

3. Dispatching
The third step ensures that operations are done successfully and everything is loaded on the software. Dispatching includes the release of orders, in accordance with the scheduled charts.

Here are the points that encapsulate “Dispatching”

  • Issue of materials or fixtures that are important for the production
  • Issue of orders or drawings for initiating the work
  • Maintain the records from start to end
  • Initiate the control procedure
  • Cascade the work from one process to another

4. Follow-up
Also known as expediting, follow-up is the final step that finds faults or defects, bottlenecks and loopholes in the entire production process. In this step, the team measures the actual performance from start till the end and then compares it with the expected one.

Expediters or stock chasers are responsible for performing follow-up process. It is quite obvious that any of the processes may undergo break-downs or machine failure. Follow-up promotes smooth production by eliminating these defects.

How can OptiProERP help manufacturers with Production Planning and Control?

OptiProERP with SAP Business One helps you convert auto-generated production proposals into work orders with a single click. Get a complete view of resource capacity, backlogs and bottlenecks, plant floor data and inventory demand on a single screen.

Plant floor workers can update the status of their tasks, managers can create issue change orders, check schedules, capacity, and manage BoMs with real-time dashboards. Work on the go with OptiProERP.