Code No.

: 420303 Set No

1
IV-B.Tech. II-Semester Examinations April 2003

PRODUCTION PLANNING AND CONTROL

(Mechanical Engineering)
Time: 3 Hours Max. Marks: 80
Answer any FIVE questions
All questions carry equal marks
---
1.a) Define (i) Production ; (ii) Production Planning ; (iii) Production Planning &
Control
b) Write about the Principles of Production Planning & Control.

2.a) Explain the type of Production “Production for stock”.

b) Explain the main factors to determine the place of Production Planning & Control
in an organization.

3. Following data refers to the past sales of one product.

Year : 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Sales : 50 62 70 85 96 96 85 96 105 120
Use least square method and estimate sales forecasting of the year 2003.

4. What is the set up cost in a manufacturing situation? What elements does it

comprise of ?

5.a) Define P – System ? When do you recommend this for controlling inventory?
b) How is the reorder point determined? What is the significance of the reorder
points to the production manager?

6.a) Define Scheduling

b) Explain different methods of scheduling

7.a) Distinguish between gantt progress chart and a gantt load chart?
b) A company has orders for five jobs A, B, C, D and E that must be processed
sequentially through two work centers baking and decoration. The time in hours
required for the jobs is shown below. Determine the schedule of sequence that
minimizes the total elapsed time for the five jobs and present it in the form of the
gantt chart.

Work centers Time required jobs (Hrs)

A B C D E
Baking 5 4 8 7 6
Decoration 3 9 2 4 6

Contd…2
Code No.: 420303 -2- Set No. 1

8.a) With the help of Organizational Charts, explain the Centralized & Decentralized
System of Dispatching.
b) List the merits & demerits of Centralized & Decentralized system of dispatching

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 Set No
Code No.: 420303

IV-B.Tech. II-Semester Examinations April 2003 2

PRODUCTION PLANNING AND CONTROL
(Mechanical Engineering)

Time: 3 Hours Max. Marks: 80

Answer any FIVE questions

All questions carry equal marks
---

1.a) Explain various advantages to the producers through Production Planning &
Control.
b) Explain the objectives of Production Planning.

2. What is “Process Planning sheet”? What is its significance? Explain it with an

example.

3. Data given below refers to the past sales of production unit for last eleven years.
Using least square method, estimate sales forecast for next two years.
Year : 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001
2002
Sales : 35 50 48 47 53 58 68 79 92 85 86
Rs(x10,000)

4.a) What is selective control of inventories?

b) Compare ABC analysis and VED analysis.

5.a) What are the characteristics of fixed order Quantity (Q) System. Illustrate with a
figure.
b) What are the Limitations & Advantages of Fixed Order Quantity (Q) System and
mention the application.

6.a) Why do you need scheduling?

b) What are the inputs of scheduling?

Contd…2
Code No.: 420303 -2- Set No. 2

7. A manufacturer has four orders on hand which he has to schedule on four

different machines. How would you schedule his orders?

Order no Order size Standard pieces per hour on machines

A B C D
1 100 1 3/2 4/5 4/3
2 200 2 1 10/11 5/3
3 50 2 4/3 1 5/2
4 75 1 4/5 2/3 5/4
Machine hours available 80 150 250 100

8.a) Explain the use of computers in Inventory control.

b) Give the specimen of Job Card. What are its uses?

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 Set No
Code No.: 420303
IV-B.Tech. II-Semester Examinations April 2003

PRODUCTION PLANNING AND CONTROL

3
(Mechanical Engineering)
Time: 3 Hours Max. Marks: 80
Answer any FIVE questions
All questions carry equal marks
---

1.a) Explain the objectives of Production Control.

b) Explain the information required by the process Planning engineer for good
process Planning.

2. Explain the type of Production “Production for customer order”.

3. Data given below refers to the past sales of production unit for last seven years.
Estimate the sales forecast for the year 2003, using exponential smoothing
constant 0.3.
Year : 1995 1996 1997 1998 1999 2000 2001
2002
Sales : (No.of units) 180 168 159 170 180 200 190
210
Take sales forecast of the year 1995 as 160. Plot the actual sales and forecasted
values on a suitable graph.

4.a) What are the advantages of ABC analysis?

b) What are the limitations of ABC analysis?
c) How VED analysis overcome the limitations of ABC analysis?

5.a) Why do we need order points? How are they related to fixed order quantity
models? How can we determine the least order point?
b) The demand for an item is uniform at a rate of 25 units per month. The fixed cost
is Rs.30 each time a production is made. The production cost is Rs.2 per unit and
inventory carrying cost is 50 paise per unit per month. If the storage cost is 3
paise per unit per month, determine how often to make a production run and of
what size?

6.a) What do you mean by Bill of material ?

b) Explain the Bill of material with Design specification chart?
 Contd…2

Code No.: 420303 -2- Set No. 3

7.a) What are the objectives of scheduling?

b) Find the sequence for the following 8 jobs that minimizes the total elapsed time
for completion of all jobs. Each job is processed in the order CAB. Find the total
elapsed time and Idle time of each machine.

Jobs 1 2 3 4 5 6 7 8
Machines
A 4 6 7 4 5 3 6 2
B 8 10 7 8 11 8 9 13
C 5 6 2 3 4 9 15 11

8.a) Explain the types of follow-up used in productive control

b) Explain how do you prepare and present report to management.

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 Set No
Code No.: 420303
IV-B.Tech. II-Semester Examinations April 2003

PRODUCTION PLANNING AND CONTROL

4
(Mechanical Engineering)
Time: 3 Hours Max. Marks: 80
Answer any FIVE questions
All questions carry equal marks
---

1.a) Explain in detail about THE PROCESS PLAN of a product.

b) Explain the common steps which are generally followed by all process planners.

2. Explain how the SIZE OF PLANTS has a relation both to the organization of the
PPC department and to its procedure.

3. A company manufacturing tractors finds that there exists a relationship between

sales of tractors and index of the agricultural income. The following data has been
collected by the company for the last five years.
Year 1998 1999 2000 2001
2002
Demand 1,00,000 1,12,000 1,50,000 1,13,000 2,80,000
Demand Index 125 140 180 200
220
a) Fit a regression line
b) Estimate the sales of tractors for the year 1993, for the given index

4. An electrical housing has an annual usage rate of 75,000 units / year, an ordering
cost Rs.800 and annual carrying charge of 15.4% of the unit price. Delivery lead
time is 2 weeks. Determine the optimal operating doctrine.

5.a) Comparison of Fixed order Quantity (Q – System) and Fixed Period Order
(P-System) System and Explain their applicability.
b) What do you mean by Fixed Periodic Review System and explain its
characteristics of the System.

6.a) What are the factors affecting Routing procedure ? Explain.

b) What is difference between routing and scheduling?
 Contd…2

Code No.: 420303 -2- Set No. 4

7.a) Explain Johnson’s rule of scheduling the sequence of jobs.

b) Six jobs are to be processed on two machines. Processing time for each job on
each machine is given below. Find the sequence of the jobs that minimizes the
total elapsed time to complete jobs. Also calculate minimum elapsed time. The
jobs are to be processed first on M1 and then on M2.

Jobs A B C D E F

Machine M1 4 8 3 6 7 5
Machine M2 6 3 7 2 8 4

8.a) Explain how do you present production delays.

b) What are the course of production delays, give examples

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