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Question to be answered
(a) Define: (i) Production (ii) Production Planning (iii) Production Planning and Control. (b) Write about the principles of Production
Planning and Control.
(a) Explain how the terms quality, quantity, time and price influences the Production system. (b) Explain Pre Planning stage.
(a) Explain the four Ms of Production. (b) Explain the Production Control function.
(a) What are the objectives for which PPC department is established in a factory system? (b) List out the planning functions and
controlling functions separately.
(a) List out at least 10 various functions of PPC department. (b) Explain any two functions in the list in detail.
(a) Explain the functions of production planning. (b) Explain the aims of production planning and control.
Explain how PPC manager executes the following functions (i) Scheduling, (ii) Inventory control, (iii) Routing.
Distinguish inventory control and scheduling functions.
Explain various functions of production control department. Draw internal organization chart of Production planning department.
For producing right quantity, right quality, at right time PPC functions is essential. Do you contradict or accept.If so, justify your
answer.
(a) Explain the Control stage. (b) Explain how to select best method of manufacture.
Explain various elements of Production Control.
What do you mean by control phase? What are the activities under this phase? Explain them in brief.
Discuss the problems of production planning and control. Explain its need from the system point of view.
What are the important characteristics of effective production planning?
Explain the advantages of Production Planning and Control.
Classify the production systems. Mention characteristics of each of those systems.
Explain the importance of PPC department in a typical production system.
(a) Explain characteristics of Job shop production system. (b) Give internal organization chart for Job shop production system.
Identify the location of PPC department in the organization chart of factory.
Explain clearly whether you would like to have staff type of organization or line type of organization for Production Planning and
Control department. Give reasons for you answer.
With reference to preplanning stage of production explain the following two terms with a real world example of your own. (a)
Marketability of product. (b) Competitiveness of a product.
Explain the departmental responsibilities of PPC.
Explain managements role in: (a) Job shop production (b) Continuous production (c) Batch production.
(a) What are the requirements of a good forecasting method? (b) What are the steps in forecasting process?
(a) Explain the importance of forecasting in an industry. (b) List and explain the qualitative methods of forecasting.
Explain various types of forecasting and their uses.
Discuss various approaches in forecasting demand for new products.
What is time series analysis? How the forecast is made from the time series? Explain its advantages and limitations.
List out the various quantitative techniques for forecasting. Explain any three of them in detail.
Explain the following types of forecasts and their uses: (a) Long Range Forecasts (b) Medium Range forecasting (c) Short range
forecasting.
Explain the methods used for short-range forecasting and long term forecasting.

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(a) Explain when judgmental techniques are used in forecasting. (b) Explain when casual forecasting method is used.
Explain the Delphi method of forecasting.
Show that in an exponential smoothing method, weight-age to the past data declines exponentially.
(a) Derive expression for smoothing constant. (b) What are the effects of smoothing constant on the quality of forecast?
Compare exponential smoothing forecast for different values of smoothing constant say a = 0.1 and a = 0.3.
(a) Explain the inventory structure. (b) Illustrate the objectives of inventory control.
(a) Explain the relationship between inventory levels and profitability. (b) How profitability is achieved by controlling inventory?
(a) What are the reasons for carrying inventories? (b) How are the inventory costs estimated and normally expressed?
(a) Explain various motives behind carrying inventory. (b) Explain various components of carrying costs and order costs.
(a) What are inventory associated costs? (b) Explain the factors affecting the inventory costs.
What are the relevant costs that management should try to balance in deciding on the size of purchase orders? How do they vary with
order size?
(a) What factors do you consider in fixing the maximum and minimum stock levels? (b) Why do we balance the conflicting objectives
of minimizing cost and maximizing service levels in inventory models (c) What are some of the benefits and costs associated with
safety stock?
Classify inventory models? Discuss briefly each one of them?
(a) What are the basic assumptions in the EOQ model? Explain the significance of EOQ formula. What are its Limitations? (b) Derive
expression for basic Economic Order Quantity (EOQ).
(a) Define P - System? When you recommend this for controlling inventory? (b) How is the reorder point determined? What is the
significance of the reorder point to the production manager?
(a) What are the characteristics of fixed order Quantity (Q) System? Illustrate with a figure. (b) What are the limitations and
advantages of Fixed Order Quantity (Q) System and mention the application.
Explain and compare the fixed order quantity and fixed order period model and state their applications.
(a) What is selective control of inventories? (b) Compare and contrast ABC and VED analysis for classifying of items.
(a) How do you classify inventories into A class, B class and C class items. (b) Mention the control procedures to be exercised on A
class, B class and C class items.
(a) Explain the procedure involved in carrying out ABC analysis. (b) What are the short comings of ABC classification?

316) (a) Explain how ABC analysis is useful in a foundry unit? (b) Explain how VED analysis is applicable for spare parts management?
317) What is meant by VED analysis? What is its significance?
(a) What are the advantages of ABC analysis? (b) What are the limitations of ABC analysis? (c) How VED analysis overcomes the
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limitations of ABC analysis?
319) Write short notes on: (a) ABC classification of inventory (b) VED analysis.
320) (a) What are the objectives of inventory management? (b) Explain VED analysis of inventory control.
321) (a) What is the difference between Q-system and P-system? (b) Distinguish between P-system and Q-system.
322) (a) Explain the rational and procedure for ABC analysis of inventory control.
(a) Define material requirement planning (MRP) (b) What are the inputs to material requirement planning (c) What are the objectives
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of MRP.
402) Explain the following inputs of MRP system: (a) Master production schedule (b) Bill of Material (c) The inventory records file.
403) (a) Explain the terminology involved in MRP system. (b) Explain the principles of MRP system.

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Explain the logic of Material Requirement Planning System? Explain with example.
(a) Explain, in detail the procedural steps involved in MRP. (b) State and explain the functions served by MRP.
(a) Explain various steps involved in MRP system. (b) What are the outputs of MRP system?
Describe the MRP process, including netting, exposing and time phasing.
(a) What information is contained in the BOM file? (b) How can load reports be used to develop material requirement plans? (c) What
does it mean for an MRP system to be nervous?
Discuss the terms product structure tree and bill of materials with an example of a clip board having the parts as press board, top
part of clip, bottom of clip, spring, pivot and rivets.
Explain Enterprise Resource Planning (ERP) logic in detail. Distinguish between RFP and COP approaches for ERP selection.
What is the purpose of modeling an enterprise? How does ERP fit in the enterprise modeling endeavor?
(a) Briefly explain the purpose and concept of Line of Balance. (b) What does the bill of materials structure mean? Explain by an
example.
Discuss the use of Line of Balance (LOB) in Production control. Explain in detail the steps involved in LOB.
(a) Distinguish between Line Balancing and Line of Balance. (b) Explain the various steps of Line of Balance technique.
With respect to LOB, explain with examples the following: (a) Objective chart (b) Program plan (c) Progress chart.
(a) What is JIT inventory system? (b) What are the elements of JIT inventory system? (c) Explain the basic principles of JIT
manufacturing system.
(a) Define routing? (b) Discuss routing procedure.
Describe the following with respect to routing: (i) Job order (ii) Move order and (iii) Tool order.
Discuss in detail the following functions of routing: (a) Interpretation of detailed drawings (b) Methods analysis and (c) Work
standards.
Write about the affect of the following on routing: (a) Manufacturing process (b) Equipment and (c) Man power.
Discuss the importance of the following functions of routing: (a) Specification of machine tools and cutting tools and (b) Estimation of
manufacturing tolerances.
How does routing in job shop production differ from continuous production system?
(a) Explain the importance of routing in production planning. (b) What are the factors affecting routing procedure? Explain.
(a) Explain in detail about the Process Plan of a product. (b) Explain the common steps which are generally followed by all process
planners.
Explain the role of: (a) Production planning engineer and (b) Industrial engineer in the preparation of process planning sheet.
Explain the role of: (a) Tool engineer (b) Estimator in the preparation of process planning sheet.
List the common information and data contained in a process sheet. Explain briefly.
Distinguish between single level bill of materials and indented bill of materials with an example for each type.
What is Process Planning sheet? What is its significance? Explain it with an example.
Distinguish between route card and route sheet. Discuss the information known from these documents. Give a model route card and a
model route sheet.
What is a route sheet? What does it contain? Explain it with an example.
Prepare the route sheet showing a feasible sequence of operations for sleeve and socket cotter joint.
Prepare the route sheet showing a feasible sequence of operations for the component shown in Figure 7.
Differentiate between routing, loading and scheduling.
(a) Define Scheduling. (b) Explain different methods of scheduling.

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Write the guidelines, which assist the preparation of schedules.


What are the differences in decision variables for scheduling in a job shop and in a batch shop?
How does scheduling in Job shops differ from High volume continuous systems? Explain in detail.
Explain the terms forward scheduling and back ward scheduling.
Explain the following techniques used for loading and scheduling: (a) Perpetual schedule and (b) Order schedule.
(a) Explain master scheduling with suitable example. (b) Explain how graphs are useful for scheduling and control problems.
Explain the following devices used for loading and scheduling: (a) Produc-Trol Board and (b) Sched-U-Graph.
(a) Explain the use of Gantt charts. (b) Explain the schedule boards and commercial devices.
Explain with a neat sketch how Gantt chart is used to show schedules. Explain the symbols used in drawing Gantt chart.
Discuss in detail the importance of Gantt chart in scheduling. Explain it with an example.
What are the variants of Gantt chart used for production control?
Distinguish between Gantt progress chart and a Gantt load chart?
(a) What is the distinction between a scheduling rule and a scheduling criterion? (b) Explain the scheduling rules with their relative
advantages and disadvantages.
What single criterion priority decision rule might you expect to find use with regard to the following: (i) An air lines ticket counter (ii) A
hospital emergency room.
Why does the SPT rule perform so well for a job shop where jobs are arriving randomly over time? Is there any negative aspect in
using the SPT rule?
Explain the following as related to scheduling: (a) Mean Flow time (b) Lateness and (c) Tardiness.
For a single processor scheduling, which procedure will minimize the following? Explain. (a) Mean flow time (b) Maximum tardiness
(c) Number of jobs late and (d) Weighted flow time.
Explain: (a) Line balancing (b) Expediting (c) Chase planning (d) Capacity balance.
Distinguish between capacity balance and line balance.
Describe any one quantitative technique used for Assembly line balancing.
Define line balancing problem. Explain Ranked Positional Weight (RPW) method for solving it.

705) What is Aggregate Planning? How does it differ from Long range Planning and short period planning? Explain with an example.
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What is the meaning of Aggregate plan? What are the objectives of aggregate plans? What are the inputs and the nature of the
outputs?
(a) Define aggregate planning. (b) What is its objective? (c) List out various strategies it uses and explain one in detail.
Place Aggregate planning in context with the term planning horizon. What is the appropriate planning horizon for aggregate planning?
Explain the procedure involved in Aggregate plan.
Under what conditions would a single-stage aggregate planning decision system be appropriate?
(a) List out the guide lines for aggregate scheduling (planning) (b) Discuss the relevant cost components involved in Aggregate
planning decisions.
Explain various pure strategies and mixed strategies used in Aggregate production plans.
When the company is manufacturing a product whose demand fluctuates in the market. What strategies it has to adopt to match
capacity and demand? Explain.
Explain any one optimization method used for Aggregate production planning.
What are the graphic methods of aggregate planning? Explain their relative advantages and disadvantages.

715) What are the various possibilities of demand that can be met by Chase planning and how they will be dealt?
(a) What is meant by Dispatching? (b) Enumerate the duties of a Dispatcher. (c) Give a list of records maintained by Dispatching
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Department?
802) Discuss in detail the sequential steps involved in dispatching.
803) (a) Explain briefly the dispatching activities. (b) Explain the necessity of close control in dispatching activities?
804) Describe the following forms used in dispatching: (a) Move order (b) Production ticket.
805) Discuss the following forms used in dispatching: (a) Tool order and (b) Job order.
806) Why is dispatching required on shop floor? Write about dispatching rules used in shop floor.
(a) With the help of an Organizational Chart, explain the Centralized and Decentralized System of Dispatching. (b) List the merits and
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demerits of Centralized and decentralized system of dispatching.
808) Differentiate between centralized and decentralized dispatching procedures.
809) (a) What is follow-up? (b) Explain the reasons for existence of follow-up functions.
810) Describe the types of follow-ups in detail.
811) How does Follow-Up differ from expediting? Explain in detail.
812) Explain the different methods used to take corrective actions in shop floor.
Describe in what way the elements of control procedure are related in the fields of production control, inventory control, inspection and
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cost control.
814) (a) Explain how to present production delays. (b) What are the causes of production delays, give examples.
815) Discuss methods of reloading progress in production plants.
816) Discuss the methods used for reloading and controlling of material utilization in machine shop.
Differentiate between dispatching and expediting and point out to what extent these differences should lead to a clear and rigid
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demarcation of responsibilities between dispatching and expediting.
818) Explain the role of computers in production planning and control?
819) Write a note on the use of computers for scheduling.
820) (a) Explain how a computer can be used to prepare a schedule chart. (b) Give the specimen of inspection card.