Production Planning and Control are necessary for the manufacturing industry. It helps manufacturers to maintain a competitive advantage in the market.
These devised strategies allow manufacturers to effectively generate a production plan, execute it, and ultimately take control of their operations through continuous improvement initiatives.
This article will examine some of the main features and objectives of planning and control in production. Also, we will cover some tools that can help in the better planning and control of production. So, let’s dive into it!
As the name suggests, production planning and control is defined as the process of planning and subsequently controlling all aspects of manufacturing and production.
This includes ordering materials, scheduling tasks, assigning employees, working on machines, and even distributing goods to end customers.
Furthermore, any production company’s success depends on solid production planning and control strategy. This is because all processes occurring within production facilities depend on each other. The proper implementation of planning and control in production can act as a growth engine.
For example, if you have scheduled jobs to start production at a certain time but do not have the material needed, you will have to delay the production of that item.
This means you may have to adjust your production schedule so your machines aren’t down while you wait for materials to arrive.
Therefore, a planning and control strategy is an essential component for any manufacturing facility looking to improve the efficiency of its operations and increase its profits.
Regarding the role and importance of planning and control in production for any industry and company, we know that planning is an essential process.
Especially in a manufacturing unit, without planning and control of production, no action can be carried out if you want to obtain a clear result of what is being produced.
The term production planning and control refers to the manufacturing unit. We have all done much planning in various ways to create our strategy.
Here, production planning means that we need to produce specific production units as well as the quantity within a particular time frame. At the same time, production control refers to some exceptional techniques to obtain maximum results from production.
There are 3 main components in production. Without these components, it would be impossible to conduct the production process smoothly. These are:
Therefore, a planning and control system in production integrates and coordinates labor, machines and materials. This coordinated system bridges to achieve efficient production that meets sales needs.
The main objectives of production planning and control are listed below:
Designs a system and plan so that production is carried out to meet the promised delivery date, with a minimum cost and quality standard.
Overall, to carry out these objectives, the production department guides production by preparing and issuing manufacturing orders that establish the use of facilities and materials.
Production Planning and Control also include assigning the optimal workforce to ensure that manufacturing orders are carried out effectively.
We highlighted the objectives for efficient planning and control in the previous point. Below are some essential functions to meet the stated objectives.
We must have the right amount of raw, manufactured and purchased materials at the right time. It is to ensure that each operation starts and finishes on time and without interruption.
In short, this function specifies:
This function is related to a detailed analysis of available production facilities in a company. It includes the calculation of equipment downtime, maintenance plans, and schedules.
It is also responsible for workforce management based on equipment availability. Therefore, the aim of analyzing the facilities is to make their availability with the least downtime due to breakdowns.
It deals with analyzing alternatives and selecting the best method for the limitations. Additionally, developing process specifications is an important aspect of production planning and control, as well as determining the sequence of operations to anticipate the limitations.
It deals with selecting the path or route the raw material must follow to be transformed into a finished product.
Functions to perform:
Once the full method and sequence of operations have been established and the process sheet for each operation is available, it is time to estimate operations.
Also, this function is carried out through an in-depth analysis of operations, methods, and routes, establishing standard times for operations using work measurement techniques.
Scheduling deals with preparing machine loading operations and setting the start and end dates for each operation.
Moreover, machines must be loaded based on their ability to perform the given task according to their capacity.
It is the execution phase of planning, where a company starts production activities by releasing orders and instructions. Furthermore, the company authorizes the start of production activities by releasing materials, components, tools, supplies and instruction sheets to the operator.
It is the control tool that keeps a close eye on the progress of the work. It is a logical step after the expedition that is called “follow-up” or “progress.”
Therefore, this step coordinates the execution of the production plan. The progress function can be divided into materials, work-in-progress, and assembly tracking.
It is a measurement control phase. Although quality control aspects are a separate function, it is significant for production planning and control both for the execution of current plans and future planning.
It forms the basis for knowing the limitations regarding methods, processes, etc., which is very useful for the evaluation phase.
This phase, although neglected, is crucial for improving productive efficiency. A thorough analysis of all factors influencing production planning and control helps identify weak points and corrective action concerning pre-planning.
Moreover, planning will be carried out by feedback. The success of this stage depends on the communication, collection and analysis of data and information.
Among the advantages of production planning and control, the following aspects stand out:
The production plan becomes the reference point for all operations in production planning and control. It is the tool that will make the manufacturing organization work as well as possible.
That is why it is essential to generate a production plan and schedule that everyone can easily understand, interpret and know.
Planning is vital, although often difficult. It is the first step in the complex process of addressing a production order but it forms the basis for measuring and meeting objectives and forecasts.
An important tool that is often used to represent the production schedule is the Gantt chart.
The move from paper calendars to spreadsheets and then to real-time integrated Gantt displays in Advanced Planning and Scheduling (APS) systems has revolutionized manufacturing production planning.
Furthermore, Gantt charts are commonly used in project and resource management. It helps to oversee production timelines, where multiple interdependent tasks must be sequenced on a timeline.
Advanced planning and scheduling (APS) software Gantt screens are advantageous for manufacturing companies.
These systems use Gantt charts to increase visibility into operations that consume resource capacity.
An APS system can be integrated directly into your ERP Software. In addition, it allows you to obtain all the necessary information and automatically create an optimized production schedule.
Enterprise Resource Planning (ERP) Software shines when we have to effectively manage resources, optimize production plans, and ensure timely deliveries. Whether it’s finance, procurement, or any other area, NYGGS ERP Software provides a centralized platform that integrates different departments. It gives planners better control over production.
We cannot forget about a critical aspect of production- inventory management. Inadequate stock levels can lead to production delays and, in the worst case, customer dissatisfaction. Therefore, ERP software provides real-time visibility of inventory levels. It allows planners to optimize stock levels to avoid stockouts or overstocks.
ERP also supports resource management by providing up-to-date information on resource availability. This allows managers to allocate resources efficiently. In addition, knowledge of the capacity of each resource in the production process provides insight into avoiding shortages and minimizing idle time.
Overall, enterprise resource planning, such as NYGGS ERP Software, plays a key role in modern production planning and control. It streamlines processes, optimizes resource utilization, improves inventory management and enhances collaboration that enables manufacturing companies to achieve excellence. If you are interested in an affordable yet feature-packed ERP, NYGGS is the right choice. You can schedule a free demo session to learn more.
To sum up, for effective and economical operation in a company’s manufacturing unit, it is essential to integrate a production planning and control system.
Production planning and subsequent control occur after the adaptation of the product design and the completion of a production process.
On the one hand, production planning is necessary for shipping, inspection, quality, inventory, supply, and equipment management.
On the other hand, production control guarantees that the production team can achieve the required production target, optimal utilization of resources, quality management and cost savings.
Q1. What is Forecasting in Production Planning and Control?
Ans. Forecasting in production is the process of predicting the future demand for particular products and the resources required to manufacture those products. Forecasts use historical data as the primary input to determine future trends. Companies use forecasting for many purposes, including anticipating future expenses and determining budget allocation.
Q2. What is the first step in Production Planning and Control?
Ans. Planning is the first step in the process. It identifies all the materials, labor, manufacturing techniques, resources and other initial details.
Q3. What is Routing in Production Planning and Control?
Ans. This is the procedure for determining the order in which operations are performed during manufacturing. It determines what work needs to be done, where it needs to be done, and how it needs to be done.
What is Production Planning and Control?
Importance of Production Planning and Control
Objectives of Production Planning and Control
Functions of Production Planning and Control
Benefits of Planning and Control in Production
Production Planning and Control Tools
How Can ERP Software Help in Production Planning and Control?
FAQs
The staff.
The materials.
The machinery.
Ensure efficient utilization of production facilities.
Coordinate the production activities of the different departments.
Maintain adequate stock of raw materials to meet production needs and delivery times at the most economical level.
Ensure the production of the right product with the right quality and at the right time.
Maintain flexibility in operations to accommodate urgent jobs or to deal with contingencies.
Ensure smooth flow of materials by eliminating any bottlenecks in production.
Coordinate labor, machinery and equipment most efficiently and economically.
Set goals and compare them to performance.
Provide alternative production strategies in case of emergencies.
Determine the nature and magnitude of the various input factors to manufacture the desired output.
Materials (quality and quantity),
Delivery dates,
Variety reduction (standardization),
Sourcing, and
Make-or-buy decisions.
Setting the route taking into account the layout.
Break down the operations to define each of them in detail.
Decide the preparation time and process time for each operation.
Better communication with suppliers for the acquisition of raw materials.
Improved customer satisfaction with regular and on-time deliveries.
Reduction of production costs by increasing efficiency.
Smooth flow of all production processes.
Decrease in investment in inventories.
Less waste of resources.