Introduction

1. Explain the importance of PPC department in a typical

production system.
2. Explain the scope of production planning and control.
3. Write about the Elements of production control
4. Explain various objectives of Production Planning
Control (PPC) department.
5. Explain various functions of Production Planning
Control (PPC) department.
6. Give the internal organization of PPC department
7. What are the advantages of production planning and
control and
8. Explain various principles and procedures of production
control?
9. Discuss different types of production systems with
suitable examples?
10. List out various aspects of production control?
Explain any three aspects in detail.
11. Explain the relationship between ‘Production
planning’ and ‘control’.
12. Explain the applications of computer in PPC.
13. Explain about the concept of ERP system
14. What is ERP system? Explain any three segments of
ERP system

Forecasting
1. What is forecasting and explain the importance of
forecasting.
2. ‘Forecasting is essential not only in business but in our
daily life also’- support the statement with brief
explanation.
3. List and explain the general principles of forecasting.
4. Explain the objectives of forecasting.
5. State the objectives of long term forecasting.
6. State the objectives of short term forecasting.
7. State the advantages and limitations of sales forecasting.
8. Name and describe the various factors affecting sales
forecasting.
9. What are different types of forecasting? Explain their
significance, merits and demerits.
10. Describe ‘Exponential Smoothing Method’ of sales
forecasting. State its advantages and limitations.
11. Describe moving average method.
12. Distinguish between the qualitative and quantitative
methods of sales forecasting techniques.
13. Explain about the method of least squares. Write its
merits and demerits.
14. A computer software firm has experienced the
following demand for its “Personal Finance” software
package

Period 1 2 3 4 5 6 7 8

Units 56 61 55 70 66 65 72 75
 i.
Develop an exponential smoothing forecast using
α=0.4 and an adjusted exponential smoothing using
α=0.4 and β=0.20
ii. Compare the accuracy of two forecasts using MAD
and cumulative error
15. A manufacturing company has monthly demand for
one of its products as follows:
Month Feb Mar Apr May Jun July Aug Sept

Demand 520 490 550 580 600 420 510 610

i. Develop a three period moving average forecast
ii. Develop three period weighted moving average
forecast with weights of 0.50, 0.30 and 0.20 for the
most recent demand values.
16. Forecast the production for next two years when the
production quantity for last ten years is as follows:
200,225,235,240,255,260,265,275,270,271. Use the
following methods and comment on results
a. Simple average
b. Moving average (3 years and 5 years)
c. Exponential smoothing for α=0.3 and 0.7
17. The cost per standardized long distance phone call
has been decreasing over time. Using the following data
for the last 8 years
Year 1 2 3 4 5 6 7 8

Standardized 3.25 3.05 2.98 2.93 2.91 2.58 2.44 2.37

Cost
 a. Use linear regression to compute an expression for
cost as a linear function of time
b. Using above equation, predict the standardized cost
for year 10
18. Reliance Ltd. has achieved the exports during 1992-
93 to 1996-97 exhibited in the following table. Compute
the exports during 2001 -2002 by the method of least
squares.

Year 1992- 1993- 1994- 1995- 1996-97

93 94 95 96

Exports 1.49 1.24 1.69 1.70 3.11

(crores)

19. Find the trend using least square method for the date
below. Also estimate demand for 1984.

Year 1975 1976 1977 1978 1979 1980 1981

Demand in 85 75 80 72 65 60 55
1000 units

20. Forecast the demand for the following series by

exponential smoothing method:

Period 1 2 3 4 5 6 7 8 9 10

Actual 10 12 8 11 9 10 15 14 16 15
Demand

21. Project the trend of sales for the next four years.
 Year 1983 1984 1985 1986 1987

Sales 120 140 150 170 190

in
Lakh

22. Forecast the demand for the following series by

exponential smoothing method by taking α = 0.3 and 0.6

Period 1 2 3 4 5 6 7 8 9 10

Actual 10 12 8 11 9 10 15 14 16 15
demand

Inventory management
1. Define inventory? Explain various functions of
inventory
2. Define inventory. What are the various types of
inventory? Why are they maintained?
3. Classify inventory models? Discuss briefly any one of
them?
4. What do you understand by the term ‘Economic Order
Quantity’? On what factors does it depend explain.
5. Explain the significance of EOQ formula. What are its
Limitations?
6. Explain P and Q systems of controlling the inventories
with neat diagrams
7. Write any seven differences between P and Q systems.
8. Explain various costs associated with inventory.
9. Explain the factors affecting the inventory costs.
10. Explain about ABC and VED analysis.
11. Compare VED analysis with ABC analysis.
12. Explain the logic of Material Requirement Planning
System? Explain with example
13. Explain about inputs and outputs of MRP system.
14. Write any four benefits of MRP.
15. What do you understand by BOM? Why they are
prepared and explain with an example.
16. Explain bills of material importance in production
control. How does it help in assembly production?
17. Explain the bill of material with design specification
chart.
18. How can load reports be used to develop material
requirement plans?
19. Explain about the MRP II system in detail?
20. The annual demand for an automobile component is
36000 units. The carrying cost is Rs. 0.50/unit/year, the
ordering cost is Rs.25.00 per order and the shortage
cost is Rs.15.00/unit/year. Find the optimal values of
the following:
i. Economic Ordering Quantity
ii. Maximum inventory
iii. Maximum shortage quantity
iv. Cycle time
21. Alpha industry estimates that it will sell 12000 units
of its product for the forthcoming year. The ordering
cost is Rs. 100 per order and the carrying cost per unit
per year is 20% of the purchase price per unit. The
purchase price per unit is Rs.50.Find
a. Economic Order quantity
b. No. Of orders per year
c. Time between successive orders.
22. If a product is to be manufactured within the
company, the details are as follows:
Annual demand rate, =24000 units
Production rate, =48000 units
 Setup cost, =Rs. 200 per setup
Carrying cost,= Rs.20/unit/year.
Find the a) EOQ and b) Cycle time
23. A company requires 10000 units of an item per
annum. The cost of ordering is rs.100 per order. The
inventory carrying cost is 20%. The unit price of the
item is Rs.10. Calculate a) the economic order quantity
b) Optimal total annual cost c) time between the orders.
24. A factory needs 36000 units annually of a component
that cost Rs.2 per unit. Cost of each order placing is
Rs.25 and inventory carrying cost is Rs.10 per year.
a. Find the economic lot size and the total
inventory cost.
b. What is the time between placing of orders?
c. The supplier offers 2% discount if a single order
is placed. Should the company accept it?



Aggregate planning
1. What is difference between an aggregate plan and a
master production schedule?
2. What is aggregate planning and Explain various
objectives of aggregate planning
3. What is the need for aggregate planning and explain
various steps in aggregate planning?
4. Write its functions, merits and demerits of Aggregate
planning
5. What is aggregate planning? What are the different
approaches to aggregate planning? Explain.
6. Explain the concept of chase planning.
7. What are the advantages and disadvantages of using a
chase demand strategy for developing an aggregate
planning?
Routing
1. Define routing. Explain the routing procedure.
2. Discuss different routing procedures.
3. What are the important factors that affecting routing
procedure.
4. List out and explain the objectives of routing.
5. List out limitations of routing
6. What is the significance of routing? Explain about the
important components of routing sheets?
7. What is route sheet? How are they prepared?
8. Distinguish between route card and route sheet.
9. What is the importance of route sheet?
10. Describe route sheet with a suitable example.
Scheduling
1. What is scheduling? What are its objectives?
2. What are the reasons for scheduling? Explain how
scheduling improves the process of production control
significantly.
3. Explain the objectives of scheduling
4. Explain about forward and backward scheduling.
5. Explain about scheduling using different scheduling
norms.
6. Write about standard scheduling policies in detail?
7. Compare and contrast different scheduling policies.
8. List out various scheduling rules and Explain at least
three of them
9. Categorize various scheduling techniques and list
significance of each method briefly
10. Explain Johnson’s rule of scheduling the sequence of
jobs.
11. What is Gantt chart? Discuss the use of Gantt chart for
scheduling purpose with an example.
12. Explain about Scheduling techniques in brief and
explain about difference with loading in detail?
13. What is the significance of loading? Explain with the
help of machine load record.
14. Describe master scheduling?
15. What is line balancing? Explain line-balancing
procedure.
16. Explain various steps of line of balancing technique.
17. Explain the techniques of Line of Balancing process.
18. List out various heuristics for line balancing problem.
Explain any one heuristic in detail with example
19. Distinguish between Line Balancing and Line of
Balance.
20. A house-painting contractor has five houses to paint.
Following are the estimated times required to paint
each house and due date for completion.

House Estimated Due date

Time
(days)

A 2.5 8

B 4 10

C 3 7

D 5 14

E 2 16

Use the Shortest Processing Time rule to sequence the five

jobs Compute average flow time and average tardiness per
job using this sequence
21. The Company needs to produce 4000 boxes of blocks
per 40 hour week to meet upcoming holiday demand.
The process of making blocks can be broken down into
six work elements. The precedence and time
requirements for each element are as follows. a) Draw
precedence diagram for the production process b)
 Determine minimum number of work stations and c)
balance efficiency.

Work Precedence Performance

element time (min)

A - 0.1

B A 0.4

C A 0.5

D - 0.2

E C, D 0.6

F B, E 0.4

22. David is an independent computer software

consultant. After completing his most recent project, he
had five jobs awaiting completion. Following are the
estimated work times required to complete each job
and due dates requested by customers

Job Processing Due

time date(days
from
present)

A 12 52

B 16 37

C 8 28
 D 20 57

E 6 31

Construct job sequences using the Shortest

Processing Time rule, Earliest Due
Date rule and Compute the average flow time.
16. At an electronics repair shop all items are first
diagnosed by an expert technician. He estimates the
amount of repair work required and assigns it to a
second technician for completion. The second
technician has five jobs awaiting work with the
expected work time required and due date listed below

Job Expected Due date

repair
time

A 5.5 8

B 6 16

C 3.5 16

D 5 20

E 4 24

Construct job sequences using the Critical ratio rule,

and Slack Time Remaining rule and Compute the
average flow time
23. The precedence and the time requirements for each
element are shown in table. The line operates for 7 hrs
per day and an output of 550 units per day is desired.
a) Draw the precedence diagram for the production
process.
b) Calculate i) cycle time and ii) Theoretical minimum
number of workstations required.
c) Group the tasks into number of workstations.
d) Calculate balance efficiency.

Work A B C D E F G
element

Precedence - A B C C D,E F

Time(min.) 0.65 0.40 0.30 0.20 0.45 0.40 0.30

24. Following data is available for processing three

orders: A, B and C. Order AJ712 was received two days
after receipt of order AJ600 and AJ720 was received one
day after receipt of order AJ712. One day is required for
setting up and material handling between each
operation. Prepare a Gantt schedule chart. There are no
machine restrictions.

Estimated time(days)

Operation Order No. Order No. Order No.

No. AJ712 AJ AJ
720 600


10 7 8 3

20 5 2 5

30 3 4 5

40 2 - -

50 1 - -

60 1 - -

17. A machine operator processes five types of products

and must choose sequence for them. The set-up cost per
change (Rs.) depends on the products presently on the
machine and the set-up be made according to the
following table. Changeovers from A to D and C to E are
not allowed. How should one sequence the products in
order to have minimum total set-up cost?

From To Product
Product A B C D E

A - 4 7 - 4

B 4 - 6 3 4

C 7 6 - 7 -

D 3 3 7 - 6
E 4 6 4 5 -

25. Describe production scheduling.

26. For the following data, find the schedule that
minimizes the mean flow time, if the number of parallel
machines is 2

Job 1 2 3 4 5 6 7 8

Processing 4 6 3 7 2 1 5 9
Time (hr)

a. Give a short note on Line of Balance.

b. What is the importance of loading?
c. What is the role of LOB in project scheduling?
27. A bomb squad faces a terrible situation that the
members wish had never happened. A terrorist has
planted five bombs in an airport building, endangering
lives and property. The squad has located all five bombs
and must now proceed to dismantle them. Because of
limited staffing, the bombs can be dismantled only
sequentially. Unfortunately, there is not much time left
and the squad must choose judiciously the order in
which the bombs will be dismantled. The following data
represents a reliable estimate by the squad. What
sequence for dismantling the bombs would you
recommend to the squad? What should be the criterion
that the squad optimizes?

Bomb 1 2 3 4 5
 Time to dismantle 3 1 2 4 1
(hours)

Time remaining before 9 11.25 11 6 5

the bomb will
explode (hours)

Dispatching
1. What is dispatching? What is its significance?
Enumerate its advantages in production control.
2. Explain the dispatching procedure in detail.
3. Explain various activities of dispatcher
4. Explain dispatching rules.
5. Explain the necessity of close control in dispatching
activities?
6. List out various forms raised by dispatcher? Explain any
three with neat sketch
7. Give a list of records maintained by Dispatching
Department?
8. Describe advantages & disadvantages of dispatching
jobs all at once and operation by operation.
9. Compare & contrast dispatching centralized control Vs.
Dispatching decentralized control
10. Write advantages and disadvantages of dispatching–
centralized and decentralized

Expediting and Follow up
1. What is expediting and explain its importance in
production planning.
2. Explain about the duties of expediter?
3. Explain various types of expediting procedures
4. What is material follow up? What is the role of purchase
department in material follow up?
5. What are the objectives follow up?
6. Describe the activities in follow up or control phase of
PPC.
7. Explain about the types of follow up in detail?