Production Control | Management Optional Notes for UPSC PDF Download

Introduction

• Production is necessary for consumer satisfaction and enhancement of firms in competitive business climate. It has been revealed in studies that production is the main activity of manufacturing enterprises. The success of firms depends on the efficiency of this activity therefore it is important to have complete control over it. Production control is defined as actions involved in handling materials, parts, assemblies, and subassemblies, from their initial stage to the finished product stage in a structured and efficient way. It may also consist of activities such as planning, scheduling, routing, dispatching, storage. 
• According to Henry Fayol, productioncontrolis an art and science of ensuring that all activities occurs are in accordance with the rules established and instructions issued (Singla, 2010). Once the industrialist has taken the decisions regarding the product design and production processes and system, the next job is to take steps for production planning and control. Under production control, an effort is made to ensure that production should by timely in proper quantity, premium quality and it should be achieved at minimum cost with low wastage. Under production control, the decision taken with regard to what, where, how are to be given practical shape and it is the main purpose of production control.

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Optimizing Production Efficiency: The Role of Production Control and Its Objectives

Production control employs standard control techniques to optimize the performance of the production system and achieve overall production planning objectives. It entails planning production activities of operations, determining the precise route for each component or assembly, establishing start and finish times for key items, assemblies, or production completion, issuing necessary orders, and ensuring smooth enterprise operations through follow-up actions. Particularly in small industries, production control is intricate. The production planning and control department can effectively operate within small-scale units when supported by the work manager, purchase manager, personnel manager, and financial controller in planning production activities. While the production controller typically reports directly to the works manager, in small-scale units, the industrialist often assumes all three functions of material control, planning, and control. Production control begins with dispatching and involves subsequent remedial actions.

Research has shown that production controls are closely linked to production planning, and control mechanisms within production plans verify that targets are met. Various production controls are utilized in large firms:

• Progress control ensures that planned output is achieved by controlling production programs and schedules.
• Cost control manages budgets, including material and labor costs, to adhere to the original production cost budget.
• Quality control maintains product quality and standards.
• Machine utilization control manages machine loading to align with machine capacity.
• Stock control oversees stock and inventory to ensure supplies are available as needed without disrupting production schedules.
• Computer control automates certain operations.

The objectives of production control include maximizing output with minimal resource input and regulating the orderly flow of materials from raw to finished stages. It focuses on controlling material flow throughout the organization and aims for proper tooling and plant layout to minimize delays and material transfer wastage. Routing work within the factory is also an objective of production control, along with inventory management and production schedule organization. The primary functions of production control are to deliver assemblies and products of required quality and quantity at specific times, monitor and provide feedback to manufacturing management, optimize resource utilization, and achieve cost reduction and reliable customer service objectives.

Significance of Production Control:

• One key aspect is ensuring plan execution. Production control enables companies to discern the variance between standard and actual results, ensuring adherence to plans. If deviations occur, corrective actions can be taken promptly.
• Moreover, production control optimizes human and physical resource utilization.
• It facilitates coordination among departments, crucial for organizational success. By monitoring production, it identifies whether orders will be met and addresses any variations, fostering inter-departmental coordination.
• Additionally, it aids in cost reduction and quality enhancement, notably through inventory management.
• Production control plays a vital role in mitigating undesirable activities such as theft, delays, and non-cooperation, ensuring safety, timely delivery, and waste reduction. Furthermore, it exerts psychological pressure on stakeholders to adhere to standards.

Techniques of Production Control:

• Programming involves planning production to ensure a smooth material flow and synchronize manufacturing operations. It encompasses decisions regarding product nature, quantity, and timing, aiming for reliable delivery, even plant and labor loading, and efficient capital use.
• Scheduling establishes a timetable for production activities, determining the time required for each process. Various schedules, such as master, operation, and daily operation schedules, are employed to maintain control.
• Dispatching involves initiating production activities by issuing orders and instructions based on planned times and sequences. It coordinates tasks across departments, ensuring availability of materials and tools, assigning work to machines and personnel, and maintaining production records. Factors like machine breakdowns and material delays significantly impact dispatching functions.

Key Documents and Duties in Production Control via Dispatching

• Job Order: This document authorizes the start of production for a batch, aligning with predetermined dates and times recorded on machine loading charts, route sheets, and control devices. It also records the time taken for each operation.
• Store Requisition: This authorizes the storekeeper to issue materials to departments for operations.
• Tool Orders: These are issued to the tool department to prepare tools, jigs, and fixtures.
• Time Tickets, Drawings, Instruction Cards: These are provided to workers to commence manufacturing operations.
• Inspection Orders: Issued to ensure quality standards are maintained throughout production.
• Internal Delivery Note: Used for delivering finished products, components, or excess materials to stores.

The dispatcher's duties include allocating work to machines, authorizing tool and material receipt, monitoring material progress, allowing material transfers between processes, issuing inspection orders, recording idle machine and manpower, and actual production.

Inspection in Production Control:

Inspection is crucial for maintaining quality standards and reducing wastage. It encompasses:

• Checking raw material quality before use.
• Inspecting machines before production.
• Ongoing inspection during production.
• Inspecting tools for optimal performance.
• Final inspection of finished products.

Progressing or Follow-up:

Follow-up involves systematic examination of production activities to ensure adherence to plans. It includes measuring output against plan, analyzing performance, and implementing corrective actions for deviations. Progressing provides early warnings for discrepancies between planned and actual production, facilitating timely corrective measures. It helps identify causes of delays and discrepancies and ensures proper synchronization of production plans.

Steps in Progressing or Follow-up include:

• Using flowcharts to depict planned operations.
• Comparing production schedules with targets.
• Using machine loading charts to track operations.
• Establishing inspection schedules.

Tasks performed in Progressing include recording actual production, comparing it with planned production, measuring production variability, and reporting discrepancies to the appropriate authority.

Conclusion

Production control involves planning production before actual activities commence and implementing control measures to ensure quality, quantity, delivery schedule, and manufacturing rate meet expectations. It maintains quality standards throughout the production lifecycle and offers benefits such as smooth process flow, cost savings, and resource optimization. Production control methods vary based on the nature, orientation, and size of operations.