Production Planning and Control (PPC): Routing, Scheduling, Dispatching, Follow-Up and Control Charts (Overview) Questions

Question 1

Define Production Planning and Control (PPC).

Accepted Answer

**Production Planning and Control (PPC)** is the function of planning production activities and controlling their execution to ensure efficient production and timely delivery.

Question 2

What is routing?

Accepted Answer

**Routing** is deciding the **path and sequence of operations** a job will follow from raw material to finished product.

Question 3

What is scheduling?

Accepted Answer

**Scheduling** is fixing the time and date for each job/operation—when it should start and finish.

Question 4

What is dispatching?

Accepted Answer

**Dispatching** is the process of issuing orders/instructions and releasing work to start production as per schedule.

Question 5

State one objective of PPC.

Accepted Answer

One objective of PPC is **timely delivery** by ensuring production follows schedules and delays are controlled.

Question 6

Write one difference between production planning and production control.

Accepted Answer

**Planning** decides what to do in advance (future plan), while **control** monitors actual work and takes corrective action to match the plan.

Question 7

Explain functions of PPC (any five).

Accepted Answer

Functions of PPC (any five):

- **Routing**: decide sequence of operations and work centers.
- **Loading**: allocate work to machines based on capacity to avoid overload.
- **Scheduling**: decide start and finish times for jobs/operations.
- **Dispatching**: release work orders and authorize start of production.
- **Follow-up/expediting**: monitor progress and remove delays.
- **Inspection/quality control**: ensure output meets specifications.
- **Corrective action and feedback**: correct deviations and update plans.

Thus, PPC connects planning with shop-floor execution and control.

Question 8

Explain routing: steps and importance (any three points).

Accepted Answer

### **Routing**

**Steps (any three):**
- identify operations required (cutting → drilling → assembly etc.).
- select machines/work centers for each operation.
- decide tools, jigs/fixtures and standard methods.
- prepare route sheet/process sheet.

**Importance:**
- ensures **systematic flow** of work.
- reduces confusion and delays on shop floor.
- helps in better scheduling and cost estimation.

Hence, routing is a basic planning activity in PPC.

Question 9

Explain scheduling and sequencing rules (FCFS, SPT, EDD) briefly.

Accepted Answer

### **Scheduling and Sequencing Rules**

- **Scheduling** fixes start and finish times of jobs/operations.

Common sequencing rules:
- **FCFS**: First Come First Serve (jobs processed in arrival order).
- **SPT**: Shortest Processing Time first (job with minimum processing time is done first).
- **EDD**: Earliest Due Date first (job with nearest due date is done first).

Thus, sequencing rules help reduce waiting and improve delivery performance depending on objective.

Question 10

Explain dispatching: activities and role in PPC (any three points).

Accepted Answer

Dispatching is releasing work to start production.

Activities/role (any three):
- issue **work orders**, route sheets and drawings.
- issue materials and tools to workstations.
- authorize start of operations and record start/finish times.
- coordinate with supervisors to ensure work begins as planned.

Hence, dispatching converts schedules into shop-floor action.

Question 11

Explain loading and sequencing in PPC (any three points).

Accepted Answer

### **Loading and Sequencing in PPC**

- **Loading** means allocating work to machines/work centers based on their **capacity** so that overloading and underloading are avoided.
- **Sequencing** means deciding the **order of jobs** on a machine (which job first, second, etc.).
- Proper loading and sequencing help to reduce **waiting time**, balance workloads and improve on-time delivery.

Examples of sequencing rules: **FCFS**, **SPT**, **EDD**.

Thus, loading and sequencing are important planning tools for smooth shop-floor flow.

Question 12

Explain inspection and quality control in PPC (any three points) with a small flow.

Accepted Answer

Inspection and quality control ensure that output meets **specifications** and prevents defects from moving to next stage.

Key points (any three):
- **Incoming inspection** checks raw material quality before production.
- **In-process inspection** detects defects early, reducing rework and scrap.
- **Final inspection** ensures finished goods meet standards before dispatch.
- If defects are found, PPC triggers **corrective action** (adjust method, machine setting, operator training).

Flow (simple):

```text
Input check → In-process check → Final check → Corrective action + feedback
```

Thus, quality control is integrated with PPC to support delivery, cost control and customer satisfaction.

Question 13

Explain follow-up (expediting) and corrective action in PPC (exam-style with flowchart).

Accepted Answer

### **Follow-up (Expediting) and Corrective Action in PPC**

**Follow-up/expediting** means continuously monitoring production progress and ensuring jobs move as per schedule.

#### **Why follow-up is needed**
- to detect delays early (machine breakdown, shortage of material, absenteeism)
- to reduce bottlenecks and idle time
- to ensure promised delivery dates are met

#### **Corrective actions (examples)**
- reschedule jobs and adjust priorities
- shift work to alternate machines or add overtime
- arrange urgent material/tools
- initiate maintenance to restore machine availability

Flowchart:

```text
Plan & schedule → Dispatch → Monitor progress (follow-up)
      ↓
Deviation found (delay/defect/shortage)
      ↓
Corrective action (reschedule/resources/maintenance)
      ↓
Back on track + feedback to planning
```

**Conclusion:** Follow-up with corrective action forms the control loop that keeps production aligned with the plan.

Question 14

Explain Gantt chart and its use in production control (exam-style with a small diagram).

Accepted Answer

### **Gantt Chart and Its Use in Production Control**

A **Gantt chart** is a bar chart that shows planned and actual timing of jobs/operations.

#### **Uses in PPC**
- shows job schedules visually (start and finish times)
- helps track progress and identify delays
- supports better coordination across work centers
- helps in rescheduling when priorities change

Small diagram (concept):

```text
Time →  Day1  Day2  Day3  Day4
Job A:  ████  ███
Job B:        ████ █
Job C:  ██    ████
```

**Conclusion:** Gantt charts make scheduling and follow-up easier by giving a clear visual picture of the production plan vs progress.

Question 15

Explain benefits and limitations of PPC (exam-style with table).

Accepted Answer

### **Benefits and Limitations of PPC (Exam-Style)**

PPC improves coordination and efficiency, but it also needs discipline and data accuracy.

Table:

| Aspect | Benefits | Limitations |
|---|---|---|
| Resource use | better utilization of men/machines | needs accurate capacity and time data |
| Flow | smoother production, fewer stoppages | frequent demand changes disturb schedules |
| Delivery | improved on-time delivery | difficult in highly customized jobs without systems |
| Cost/Inventory | reduced WIP and waste | requires trained staff and implementation effort |

**Conclusion:** PPC is essential for efficient production, but success depends on accurate information, trained people and consistent follow-up.

Production Planning and Control (PPC): Routing, Scheduling, Dispatching, Follow-Up and Control Charts (Overview)

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