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CONTENTSTopic page no.1. Title Summary 62. Introduction 73. Company Profile 8 - 214. Objectives of the Study 225. Production Function 23-246. Steps in PPC 25-30 7. Problems with Traditional Production Planning and Control 31-3210. Production Planning and Control at R.L. MASAALA 33-4611. Research Methodology 4712. Interpretation of Data 48-5713. Findings 5814. Conclusion 5915. Recommendation 6016. Bibliography 6117. Annexure 62-63

Project Title HOW TO SMOOTHING THE PROCESS OF PRODUCTION, THROUGH PLANNING AND BETTER SUPERVISION

Title Summary: The project has been developed to identify the need and importance of PPC i.e. Production Planning and Control in manufacturing industry. Production planning is done with the objective of coordination of materials with suppliers, efficient utilization of people and machines, efficient flow of materials, and communication with customers.

Various activities are supported by Production Planning and Control like- Materials Planning, Purchasing, Raw Material, Inventory Control, Capacity Planning, Scheduling Machine and People, WIP Inventory Control, Coordinate Customer Orders, Finished Goods Inventory Control.

Production planning and control facilitates in various ways like- optimum utilization of capacity, inventory control, ensures quality, and economy in production time.

Production Planning is accompanied with Control Mechanism to ensure desired results. Results are compared with plans, if any deviation is found revision of plan is done. Hence, Production Control is an adjusting process, providing corrective measures for planned development.

INTRODUCTION

India is known as The home of spices. No Indian meal is considered complete without the tangy and delectable flavor of Indian spices, locally known as Masala. Indian spices are famous all over the world for their gastronic value and them known to possess high medicinal values. There is no other country in the world that produces as many kinds of spices as India. Some of the most widely consumed spices in the country inter alia include: chilli, cinnamon, cumin, curry leaf, fennel, asafetida, basil, bay leaves, cardamom-small, cardamom-large, ginger, mustard, bishops, weed, cassia, celery, clove, coriander, fenugreek, garlic, mint, onion, parsley, pomegranate, turmeric, tamarind, pepper, poppy, rosemary and vanilla. The climate of the country is found suitable for growing almost all spices. India produces 25 lakhs tone to 30 lakhs tonne of spices annually. India produces spices of different categories worth around Rs.14, 000 crore. In terms of volume India accounted for 46 percent and 23 percent in value of global spice trade. India accounts for 25-30 percent of worlds pepper production, 35 percent of ginger and about 90 percent of turmeric production.

There are few things that permeate Indian life so completely as spices. The aroma, colour, taste and texture of the astonishing varieties of spices in India nourish a rich variety of cuisines and cultures.

There are few things that permeate Indian life so completely as spices. The aroma, colour, taste and texture of the astonishing varieties of spices in India nourish a rich variety of cuisines and cultures.

Earlier, spices were chosen, measured, pounded and mixed, all in the kitchen. It took hours to prepare these spice recipes passed down by generations. Today, millions of homes enjoy the same authentic taste and aroma of traditional delicacies, with Everest's perfect blend of pure spices. These blends even bring the regions closer by providing the authentic taste of other regional cuisines, in the convenience of a pack, at home.

Cardamom

Cardamom

True Cardamom (Elettaria cardamomum)

Scientific classification

Kingdom:Plantae

(unranked):Angiosperms

(unranked):Monocots

(unranked):Commelinids

Order:Zingiberales

Family:Zingiberaceae

Genera

AmomumElettaria

Cardamom(orcardamon) refers to several plants of the similargeneraElettariaandAmomumin thegingerfamilyZingiberaceae. Both genera are native toIndia,Pakistan,NepalandBhutan; they are recognised by their small seed pods, triangular in cross-section and spindle-shaped, with a thin, papery, outer shell and small black seeds.Guatemalais the biggest producer and exporter of cardamom in the world, followed by India. Some other countries, such asSri Lanka, have also begun to cultivate it.Elettariapods are light green whileAmomumpods are larger and dark brown.It is the world's third most expensivespiceby weight, outstripped in market value only bysaffronandvanilla Etymology[edit]The word "cardamom" is derived from theLatincardamomum, itself thelatinisationof theGreek(kardamomon), a compound of(kardamon), "cress" +(amomon), which was the name for a kind of an Indian spice plant. The earliest attested form of the word is theMycenaean Greekka-da-mi-ja, written inLinear Bsyllabic script, in the list of flavourings on the "Spice" tablets found among palace archives in the House of the Sphinxes inMycenae.

In theNew Testament(which was largely written in Greek), the nameamomon[] appears in reference to an aromatic plant. This could be derived - and some books state so - from the adjective amomos [] "blameless, without reproach"; given, however, that amomos is a regional and poetic form, this may be less probable than (what other books state) the derivation from Aramaic hemama, which was not able to be verified.The modern genus nameElettariais derived from the local name in a South Asian tongue; cf. Hindi ilaychi and Punjabi ilaichi "green cardamom". The common source is Sanskrit, where cardamom is called ela or ellka which is itself a loan from a Dravidian language. From the corresponding Dravidian root, L, all modern names of cardamom in the major Dravidian languages are directly derived, e.g., Kannada elakki [], Telugu yelakulu, Tamil elakkai and Malayalam elakkay The second element kai means "vegetable".

Types and distribution

Green and black cardamomThe two main genera of the ginger family named as forms of cardamom are distributed as follows:Elettaria(commonly called cardamom, green cardamom, or true cardamom) is distributed from India to Malaysia.Amomum(commonly known asblack cardamom, brown cardamom,kravan, Java cardamom, Bengal cardamom, Siamese cardamom, white cardamom, or red cardamom) is distributed mainly inAsiaand Australia.The two types of cardamom, and , were distinguished in the fourth century BCE by the Greek father of botany,Theophrastus. Some of his informants told him that these varieties came to Greece from the land of theMedesin northern Persia, while others were aware it came originally from India.

Ecology Elettaria cardamomumis used as a food plant by thelarvaeof themothEndoclita hosei. Varieties

Cardamom plant

There were initially three natural varieties of green cardamom plants.Malabar (Nadan/Native), as the name suggests, is the native variety ofKerala. These plants havepanicleswhich grow horizontally along the ground.Mysore, as the name suggests, is a native variety ofKarnataka. These plants have panicles which grow vertically upwards. The mysore variety has however declined in the past few decades owing to the emergence of the more resistant and better yielding "Green Gold" variety, and which is most commonly form of cardamom harvested in Kerala.Vazhuka is a naturally occurring hybrid between Malabar and Mysore varieties, and the panicles grow neither vertically nor horizontally, but in between.Recently, a few planters isolated high-yielding plants and started multiplying them on a large scale. The most popular high-yielding variety is 'Njallani'. 'Njallani, also known asrup-ree-t, is a unique high-yielding cardamom variety developed by an Indian farmer, Sebastian Joseph, atKattappanain the South Indian state ofKerala. K. J. Baby ofIdukki district, Kerala, has developed a purely white flowered variety of Vazhuka type green cardamom having higher yield than Njallani. The variety has high adaptability to different shade conditions and can also be grown in waterlogged areas. Uses

Both forms of cardamom are used as flavorings in both food and drink, as cooking spices and as a medicine.E. cardamomum(green cardamom) is used as a spice, a masticatory, and in medicine; it is also smoked sometimes.

Food and drink

Spice shop in Sri LankaCardamom has a strong, unique taste, with an intensely aromatic, resinous fragrance. Black cardamom has a distinctly more smokey, though not bitter, aroma, with a coolness some consider similar to mint.Green cardamom is one of the most expensive spices by weight, but little is needed to impart flavor. It is best stored in pod form because once the seeds are exposed or ground, they quickly lose their flavor. However, high-quality ground cardamom seed is often more readily (and cheaply) available and is an acceptable substitute. Grinding the pods and seeds together lowers both the quality and the price. For recipes requiring whole cardamom pods, a generally accepted equivalent is 10 pods equals 1 teaspoons of ground cardamom.

It is a common ingredient in Indian cooking and is often used inbakinginNordic countries, such as in the Finnish sweet breadpullaor in the Scandinavian breadJulekake. In theMiddle East, green cardamom powder is used as a spice for sweet dishes, as well as traditional flavouring in coffee and tea. Cardamom pods are ground together with coffee beans to produce a powdered mixture of the two, which is boiled with water to make coffee. Cardamom is used to some extent in savoury dishes. In some Middle Eastern countries, coffee and cardamom are often ground in a wooden mortar, amihbaj, and cooked together in a skillet, amehmas, over wood or gas, to produce mixtures as much as 40% cardamom.In South Asia, green cardamom is often used in traditionalIndian sweetsand inmasala chai(spiced tea). Black cardamom is sometimes used ingaram masalafor curries. It is occasionally used as a garnish in basmati rice and other dishes. It is often referred to as fat cardamom due to its size. Individual seeds are sometimes chewed and used in much the same way as chewing gum. It is even used by confectionery giantWrigley; its Eclipse Breeze Exotic Mint packaging indicates that it contains "cardamom to neutralize the toughest breath odors." It has been known to be used forginmaking and inherbal teas.Traditional medicine.

Cardamom (Elettaria cardamomum) essential oil in clear glass vial

Green cardamom is broadly used in South Asia to treat infections in teeth andgums, to prevent and treat throat troubles, congestion of the lungs and pulmonarytuberculosis, inflammation of eyelids and alsodigestivedisorders. It also is used to break up kidney stones and gall stones, and was reportedly used as anantidotefor both snake and scorpionvenom.Amomumis used as a spice and as an ingredient in traditional medicine in systems of thetraditional Chinese medicineinChina, inAyurvedain India, Pakistan, Japan,KoreaandVietnam. Species in the genusAmomumare also used in traditionalIndian medicine. Among other species, varieties and cultivars,Amomum villosumcultivated in China, Laos and Vietnam is used in traditional Chinese medicine to treat stomach issues,constipation,dysentery, and other digestion problems.TsaokocardamomAmomum tsao-kois cultivated inYunnan, China and northwest Vietnam, both for medicinal purposes and as a spice.Main constituents:The content of essential oil in the seeds is strongly dependent on storage conditions, but may be as high as 8%. In the oil were found-terpineol45%,myrcene27%,limonene8%,menthone6%,-phellandrene3%,1,8-cineol2%,sabinene2% andheptane2%. (Phytochemistry, 26, 207, 1987) Other sources report 1,8-cineol (20 to 50%),-terpenylacetate(30%), sabinene, limonene (2 to 14%) andborneol.In the seeds of round cardamom from Jawa (A. kepulaga), the content of essential oil is lower (2 to 4%), and the oil contains mainly 1,8 cineol (up to 70%) plus-pinene(16%); furthermore,-pinene, -terpineol andhumulenewere found.World production[edit]Guatemala is the largest producer of cardamom in the world, with an average annual yield of between 25,000 to 29,000 metric tons. India is the second producer worldwide (formerly the largest ), generating approximately 15,000 metric tons annually. Cardamom was first introduced to Guatemala in 1914. Increased demand since the 1980s, principally from China, for bothAmomum villosumandAmomum tsao-kohas provided a key source of income for poor farmers living at higher altitudes in localized areas of China, Laos and Vietnam, people typically isolated from many other markets.Nepalwas previously the world's largest producer of large cardamom. According to estimates of theAsociacin de Cardamomeros de Guatemala (Cardegua) the harvest of 2012 will reach to about 29,000 metric tons, 12 percent more than in 2011 when they were 26,000 metric tons.

Gallery

Cardamom flower

Cardamom fruit and seeds

Green cardamom pods and seeds

Jar of green cardamom

White cardamom pods in a bowl

Cardamom pods as used as a spice in India

OBJECTIVES OF THE STUDY

Objective of the study is to prove that the production planning and control practices has impact on the efficient utilization of the resources, waste reduction, reduce waiting time and processing, thus contributing to the profitability of the industry. On these premise the study accentuated to address questions in order to achieve the following objectives:(1)To know how the production planning contributes to the efficient use of facilities and equipments.

(2)To know the effects of Production Planning and Control on Production function.

(3)To know whether production planning and control practices lead to waste reduction and increased profit.

(4)To prove that short term production planning and scheduling techniques employed by industries, is necessary in minimizing process and customer waiting time.

PRODUCTION FUNCTION

After taking decisions about the type of business, its location, layout etc. the entrepreneur steps into the shoe of production manager and attempts to apply managerial principles to the production function in an enterprise. Production is a process whereby raw material is converted into semi finished products and thereby adds to the value of utility of products, which can be measured as the difference between the value of inputs and value of outputs.

Production function encompasses the activities of procurement, allocation and utilization of resources. The main objective of production function is to produce the goods and services demanded by the customers in the most efficient and economical way. Therefore efficient management of the production function is of utmost importance in order to achieve this objective. Production management involves the managerial decisions regarding design of the product and design of the production system i.e. determination of production processes and production planning and control.

PRODUCTION PLANNING AND CONTROL

Once the entrepreneur has taken the decisions regarding the product design and production processes and system, his next task is to take steps for production planning and control, as this function is essentially required for efficient and economical production.Planned Production is the ability to look ahead, organize and coordinate and having plenty of driving force and capacity to lead and ability to supervise and coordinate work and simulates his associates by means of a program of human relation and organization of employees.

Production Planning and Control involve generally the organization and planning of manufacturing process. Especially it consists of the planning of routing, scheduling, dispatching inspection, and coordination, control of materials, methods machines, tools and operating times. The ultimate objective is the organization of the supply and movement of materials and labour, machines utilization and related activities, in order to bring about the desired manufacturing results in terms of quality, quantity, time and place.

Production planning without production control is like a bank without a bank manager, planning initiates action while control is an adjusting process, providing corrective measures for planned development. Production control regulates and stimulates the orderly how of materials in the manufacturing process from the beginning to the end.

STEPS IN PPC (PRODUCTION PLANNING AND CONTROL)

Production Planning and Control (PPC) is a process that comprises the performance of some critical; functions on either side, viz., planning as well as control

Production planning

Production planning may be defined as the technique of foreseeing every step in a long series of separate operations, each step to be taken at the right time and in the right place and each operation to be performed in maximum efficiency. It helps entrepreneur to work out the quantity of material manpower, machine and money requires for producing predetermined level of output in given period of time.

Routing

Under this, the operations, their path and sequence are established. To perform these operations the proper class of machines and personnel required are also worked out. The main aim of routing is to determine the best and cheapest sequence of operations and to ensure that this sequence is strictly followed. In small enterprises, this job is usually done by entrepreneur himself in a rather adhoc manner. Routing procedure involves following different activities.

(1) An analysis of the article to determine what to make and what to buy.(2) To determine the quality and type of material(3) Determining the manufacturing operations and their sequence.(4) A determination of lot sizes(5) Determination of scrap factors(6) An analysis of cost of the article(7) Organization of production control forms.

Scheduling

It means working out of time that should be required to perform each operation and also the time necessary to perform the entire series as routed, making allowances for all factors concerned. It mainly concerns with time element and priorities of a job. The pattern of scheduling differs from one job to another which is explained as below:

Production schedule

The main aim is to schedule that amount of work which can easily be handled by plant and equipment without interference. Its not independent decision as it takes into account following factors.

(1) Physical plant facilities of the type required to process the material being scheduled.(2) Personnel who possess the desired skills and experience to operate the equipment and perform the type of work involved.(3) Necessary materials and purchased parts.

Master Schedule

Scheduling usually starts with preparation of master schedule which is weekly or monthly break-down of the production requirement for each product for a definite time period, by having this as a running record of total production requirements the entrepreneur is in better position to shift the production from one product to another as per the changed production requirements. This forms a base for all subsequent scheduling acclivities. A master schedule is followed by operator schedule which fixes total time required to do a piece of work with a given machine or which shows the time required to do each detailed operation of a given job with a given machine or process.Manufacturing schedule: It is prepared on the basis of type of manufacturing process involved. It is very useful where single or few products are manufactured repeatedly at regular intervals. Thus it would show the required quality of each product and sequence in which the same to be operated.

Scheduling of Job to order manufacturing

Scheduling acquires greater importance in job to order manufacturing. This will enable the speedy execution of job at each center point.As far as small scale industry is concerned scheduling is of utmost importance as it brings out efficiency in the operations and s reduces cost price. The small entrepreneur should maintain four types of schedules to have a close scrutiny of all stages namely an enquiry schedule, a production schedule, a shop schedule and an arrears schedule out of above four, a shop schedule is the most important most suited to the needs of small scale industry as it enables a foreman to see at a glance.

1. The total load on any section2. The operational sequence3. The stage, which any job has reached.

Loading

The next step is the execution of the schedule plan as per the route chalked out it includes the assignment of the work to the operators at their machines or work places. So loading determines who will do the work as routing determines where and scheduling determines when it shall be done. Gantt Charts are most commonly used in small industries in order to determine the existing load and also to foresee how fast a job can be done. The usefulness of their technique lies in the fact that they compare what has been done and what ought to have been done.Most of a small scale enterprise fails due to non-adherence to delivery schedules therefore they can be successful if they have ability to meet delivery order in time which no doubt depends upon production of quality goods in right time. It makes all the more important for entrepreneur to judge ahead of time what should be done, where and when thus to leave nothing to chance once the work has begun.

Production control

Production control is the process of planning production in advance of operations, establishing the extract route of each individual item part\ or assembly, setting, starting and finishing for each important item, assembly or the finishing production and releasing the necessary orders as well as initiating the necessary follow-up to have the smooth function of the enterprise. The production control is of complicated nature in small industries. The production planning and control department can function at its best in small scale unit only when the work manager, the purchase manager, the personnel manager and the financial controller assist in planning production activities. The production controller directly reports to the works manager but in small scale unit, all the three functions namely material control, planning and control are often performed by the entrepreneur himself production control starts with dispatching and ends up with corrective actions.

Dispatching

Dispatching involves issue of production orders for starting the operations. Necessary authority and conformation is given for:

1. Movement of materials to different workstations.2. Movement of tools and fixtures necessary for each operation.3. Beginning of work on each operation.4. Recording of time and cost involved in each operation.5. Movement of work from one operation to another in accordance with the route sheet.6. Inspecting or supervision of work

Dispatching is an important step as it translates production plans into production.

Follow up

Every production program involves determination of the progress of work, removing bottlenecks in the flow of work and ensuring that the productive operations are taking place in accordance with the plans. It spots delays or deviations from the production plans. It helps to reveal detects in routing and scheduling, misunderstanding of orders and instruction, under loading or overloading of work etc. All problems or deviations are investigated and remedial measure are undertaken to ensure the completion of work by the planned date.Inspection: This is mainly to ensure the quality of goods. It can be required as effective agency of production control.Corrective measures: Corrective action may involve any of those activities of adjusting the route, rescheduling of work changing the workloads, repairs and maintenance of machinery or equipment, control over inventories of the cause of deviation is the poor performance of the employees. Certain personnel decisions like training, transfer, demotion etc. may have to be taken. Alternate methods may be suggested to handle peak loads.

Inspection

This is mainly to ensure the quality of goods. It can be required as effective agency of production control.

Corrective measures

Corrective action may involve any of those activities of adjusting the route, rescheduling of work changing the workloads, repairs and maintenance of machinery or equipment, control over inventories of the cause of deviation is the poor performance of the employees. Certain personnel decisions like training, transfer, demotion etc. may have to be taken. Alternate methods may be suggested to handle peak loads.

Problems with Traditional Production Planning and Control

There are many problems that occur during the cycle of activities in the traditional approach to production planning and control. Many of these problems result directly from the inability of the traditional approach to deal with the complex and ever-changing nature of manufacturing. The types of problems commonly encountered in the planning and control of production are the following:

1. Plant capacity problems

Production falls behind schedule due to a lack of labor and equipment. This results in excessive overtime, delays in meeting delivery schedules, customer complaints, backordering, and other similar problems.

2. Suboptimal production scheduling

The wrong jobs are scheduled because of a lack of clear order priorities, inefficient scheduling rules, and the ever-changing status of jobs in the shop. As a consequence, production runs are interrupted by jobs whose priorities have suddenly increased, machine setups are increased, and jobs that are on schedule fall behind. 3. Long manufacturing lead times

In an attempt to compensate for problems 1 and 2, production planners allow extra time to produce an order. The shop becomes overloaded, order priorities become confused, and the result is excessively long manufacturing lead times. 4. Inefficient inventory control

At the same time that total inventories are too high for raw materials, work-in-progress, and finished products, there are stock outs that occur on individual items needed for production. High total inventories mean high carrying costs, while raw material stock outs mean delays in meeting production schedules.5. Low work centre utilizationThis problem results in part from poor scheduling (excessive product changeovers and job interruptions), and from other factors over which plant management has limited control (e.g., equipment breakdowns, strikes, reduced demand for products).

6. Process planning not followedThis is the situation in which the regular planned routing is superseded by an ad hoc process sequence. It occurs, for instance, because of bottlenecks at work centers in the planned sequence. The consequences are longer setups, improper tooling, and less efficient processes. 7. Errors in engineering and manufacturing records Bills of materials are not current, route sheets are not up to date with respect to the latest engineering changes, inventory records are inaccurate, and production piece counts are incorrect.

8. Quality problemsQuality defects are encountered in manufactured components and assembled products, resulting in rework or scrapped parts, thus causing delays in the shipping schedule.

PRODUCTION PLANNING AND CONTROL AT R.L.MASAALA

Production plan is crucial to the success of any producing unit; it is an activity which is continues in nature and required to be revised time to time as per the requirements. It cant be done in isolation by a particular department; rather it is an integrated activity done by Planning and Control Department in collaboration with Material Department, Production Department, and Quality Control Department.

RESEARCH METHODOLOGY

Research methodology is a science of studying how research is done scientifically. It is a way to systematically solve the research problem by logically adopting various steps. Methodology helps to understand not only the products of scientific inquiry but the process itself. It also aims to describe and analyze methods, throw light on their limitations and resources and clarify the consequences, relating their potentialities to the twilight zone at the frontiers of knowledge.In the making of this project I adopted the following methodology:

PRIMARY DATACollection of data through questionnaireCollection of data through interview with the employees.Collection of data through factory visit.

SECONDARY DATAData collection through the industrys website.Data collection through books.

SAMPLING

Sample size 15

INTERPRETATION OF DATA

Q1. Which is the first step in a manufacturing planning and control system?

Production planningAchieving the forecastMaintaining the required inventory levelMaintaining the planned block log

OptionsABCD

Response6711

Interpretation

On the basis of 15 respondent 46% respondent said that the first step of manufacturing should be forecasting and 40 % of the respondent give their response in favour of production planning.

Q2. Do you think production planning and control is central to the success of any Manufacturing unit?

Yes No

OptionsYesNo

Response150

Interpretation

All the 100% respondents believe that production planning and control is central to the success of any manufacturing unit. Production planning and control gives direction to the best use of capacity with optimum utilization of production line, resources, and other equipments. It helps in waste reduction and leads to increased profitability.

Q3. What are the main objectives of Production Planning?a. Optimum utilization of capacityb. Inventory controlc. Economy in production timed. Ensure qualitye. Waste reduction and increased profit

OptionsABcdE

Response43215

Interpretation

All the respondents believe that waste reduction and increased profit is the main objective of production planning, some of them also believe that optimum utilization of capacity is another objective of production planning.

The other objective of production planning is inventory control, economy in production time, and quality insurance.

Q4. Capacity planning contributes to the efficient use of facilities and equipments?

YesNo

OptionsYesNo

Response123

Interpretation

Most of the respondents i.e. 80% are in favor of the statement that capacity Planning contributes to the efficient use of facility and equipments.

Proper Capacity planning leads to optimum utilization of capacity reduces idle time, under or over utilization of capacity.

Q5. Production Planning and Control makes the supervisor ineffective?Yes No

OptionsYesNo

Response312

Interpretation

80% of respondents are against this statement because supervisor makes the production planning and control effective with the use of various methods of PPC.

Q6. The causes of inability to meet delivery date originally promised due to :-

a) Lack of availability of material in time

b) Lack of availability of supervisor in timec) Lack of staffing shift

d) Load balancing not done properly

OptionsABCD

Response6342

InterpretationThe causes of inability to meet delivery date originally promised were not fulfilled mainly because lack of availability of materials in time and lack of staffing shift.Load balancing and supervisors not presence also may effect to meet the delivery date.

Q7. On what basis do you plan your production?

a. Customer needsb. Target of marketing departmentc. Resources availabled. Others

OptionsABCD

Response8340

Interpretation

According to the data collected from the respondents the production planning of R.L.MASAALA is based on customer need i.e. dealers demand for particular product.

The marketing department reports to the PPC/Store about dealers requirements. PPC/Store communicates with the material department about availability of material. Hence, market demand and availability of resources is considered as base for production plans.

Q8. If results are not according to the plans, what control measures are taken?a. Revision of planb. Any other measures

OptionsAB

Response132

Interpretation

If the results are good there is no need to change any plan in their production policy. If revision of the plan takes lot of time then we should go for other measures also. At present people of R.L.MASAALA do not have any other solution except revision of plan to control deviations in plans and results.

Q9. Being capable to adjust their production facilities shortly just after change in demand for products and without incurring heavy expenses, greater flexibility in production is provided by:-

a) Continuous productionb) Job and batch productionOptionsAB

Response411

InterpretationGreater flexibility in production is provided by job and batch production because in it the production has been done in lots on the basis of the order taken so the maintenance cost of inventory is very less and it leads to the effective way of production.

Q10. Do you feel or experienced hung up and bottlenecks in implementing Production Plans.YesNoOptionsYesNo

Response123

Interpretation

80% of the respondents realize that they feel various difficulties while implementing production plans.

FINDINGS

The PPC department of R.L. MASAALA believes in making plans and decisions in cooperation with production department, marketing department, material department, and quality control department. So that a feasible plan can be made, executed properly, and optimum results can be achieved. Hence, production planning and control is an integrated activity and cant be done in isolation by any particular department.

Following are the findings of this project about production planning and control activities of R.L. MASAALA:

1. Production Planning is an integrated activity and cannot be done in isolation by a particular department.2. PPC helps in scheduling tasks and production runs and ensures production capacity does not remain idle.3. The work should not be piled up but should be done when it arises.4. Proper PPC helps to resort to just- in- time systems and thereby reduce the overall inventory. It enables to ensure that the right supplies are available at the right time.5. PPC helps to reduce the cycle time and increase the turnover via proper scheduling.6. PPC provide for adherence to the quality standards so that quality of output is ensured.

To sum up we may say that PPC is of immense value to the entrepreneur in capacity utilization and inventory control. More importantly it improves his response time and quality. As such effective PPC contributes to time, quality and cost parameters of entrepreneurial success.

CONCLUSION

After doing this project I am in a position to conclude that R.L. MASAALA has well defined and structured production planning system. PPC defines the sequences and schedules of operations; hence production planning contributes to the efficient use of facilities and equipments.Production Planning and Control is done to identify production process which leads to reduced lead time; hence customer waiting time is also reduced. Production Planning and Control ensures optimum utilization of production capacity, material, and other equipments; hence it leads to waste reduction and increased profits.Proper PPC helps to resort to just- in- time systems and thereby reduce the overall inventory. It enables to ensure that the right supplies are available at the right time. Production Planning and Control helps to reduce the cycle time and increase the turnover via proper scheduling. Production Planning and Control provide for adherence to the quality standards so that quality of output is ensured.Sufficient safety stock must be maintained to meet unforeseen hindrances in the production process. The industry should be providing time to time reminders to the farmers and vendors so that they are aware about their responsibilities which would reduce the lead time.The industry could also involve third party logistics for their procurement and distribution processes from farther areas to reduce time gap and cost.

RECOMMENDATIONS

The production planning and control of R.L. MASAALA, highly depends on the material availability. In case of shortage of material the overall plan get disturbed. If such problem prevails the optimum results cannot be achieved. To avoid such problem following measures can be taken:

a. Proper Materials Planning should be done.b. R.L. MASAALA purchases materials directly from the farmers, but at the time of an emergency they should be in contact with some vendors.c. Sufficient safety stock must be maintained to meet unforeseen hindrances in the production process.d. The industry should be providing time to time reminders to the farmers and vendors so that they are aware about their responsibilities which would reduce the lead time.e. The industry could also involve third party logistics for their procurement and distribution processes from farther areas to reduce time gap and cost.f. The industry can also involve themselves in expansion process as there is an opportunity for growth in this sector.g. As there is not much awareness about R.L. MASAALA, the company should undertake marketing and promotional programs.

BIBLIOGRAPHY

INTERNET

BOOKS Stephen N. Chapman The fundamentals of production planning and control (First Edition) Year of Publication 2005, Pearson Education India, pg no. (7-22), (60-88),(146-170,)(189-216) S. N. CHARY Production and Operations Management (Second Edition) Year of Publication 2000,Tata Mc graw- Hill Publishing Company Limited, page no-(1-8),(136-140),(181-186),( 247-253) S.A. Chunawalla and D.R. PATEL Production and Operation Management (Seventh Edition) Year of Publication 2008, Himalaya Publishing House, pg no. (1-15),(22-34),(125-143),(147-166),(220-337) P. Rama Murthy Production and Operation Management (Second Edition) Year of Publication 2005, New Age International Publishers, pg no. (2-11),(19-26),(44-70),(97-136),(213-243),(332-366) R. Panneerselvam Production And Operations Management (Third Edition) Year of Publication 2012, PHI Learning Private Limited, pg no. (16-27), (54-89), (132-177), (243-267)

ANNEXURE

Q1. Which is the first step in a manufacturing planning and control system?a) Production planningb) Achieving the forecastc) Maintaining the required inventory leveld) Maintaining the planned block log

Q2. Do you think production planning and control is central to the success of any Manufacturing unit?a) Yesb) No

Q3. What are the main objectives of Production Planning?a) Optimum utilization of capacityb) Inventory controlc) Economy in production timed) Ensure qualitye) Waste reduction and increased profit

Q4. Capacity planning contributes to the efficient use of facilities and equipments?a) Yesb) No

Q5. Production Planning and Control makes the supervisor ineffectivea) Yes b) No

Q6. The causes of inability to meet delivery date originally promised due to :-

a) Lack of availability of material in time

b) Lack of availability of supervisor in timec) Lack of staffing shiftd) Load balancing not done properly

Q7. On what basis do you plan your production?

a) Customer needsb) Target of marketing departmentc) Resources availabled) Others

Q8. If results are not according to the plans, what control measures are taken?

a) Revision of planb) Any other measures

Q9. Being capable to adjust their production facilities shortly just after change in demand for products and without incurring heavy expenses, greater flexibility in production is provided by:-

a) Continuous productionb) Job and batch production

Q10. Do you feel or experienced hung up and bottlenecks in implementing Production Plans?

a) Yesb) No