Q.no 1-

What the function are typically performed by a production control department ?

Ans –

Production control department responsibilities consist of

1. Loading—checking the availability of material, machines, and labour. The MRP system

plans for material availability. CRP converts the material plan into machine and

labour requirements, and projects resource overloads and under loads. Production

control assigns work to individual workers or machines, and then attempts to

smooth out the load to make the MRP schedule "doable." Smoothing the load is

called load levelling.

2. Sequencing—releasing work orders to the shop and issuing dispatch lists for individual

machines. MRP recommends when orders should be released (hence the name,

planned order releases). After verifying their feasibility, production control actually

Releases the orders. When several orders are released to one machine center, they must

be prioritized so that the worker will know which ones to do first. The dispatch list

contains the sequence in which jobs should be processed. This sequence is often based

on certain sequencing rules.

3. Monitoring—maintaining progress reports on each job until it is completed. This is

important because items may need to be rescheduled as changes occur in the system.

In addition to timely data collection, it involves the use of Gantt charts and input/output

control charts.

Q.no 2 –

Explain Johnsons rule and its Procedure .

Ans-Since few factories consist of just one process, we might wonder if techniques exist that will

produce an optimal sequence for any number of jobs processed through more than one

machine or process. Johnson's rule finds the fastest way to process a series of jobs through a

two-step system in which every job follows the same sequence through two processes. Based

on a variation of the SPT rule, it requires that the sequence be "mapped out" to determine

the final completion time, or makespan, for the set of jobs. The procedure is as follows:

1. List the time required to complete each job at each process. Set up a one-dimensional

matrix to represent the desired sequence with the number of slots equal to the number

of jobs.

2. Select the smallest processing time at either process. If that time occurs at process 1,

put the associated job as near to the beginning of the sequence as possible.

3. If the smallest time occurs at process 2, put the associated job as near to the end of the

sequence as possible.

4. Remove the job from the list.

5. Repeat steps 2-4 until all slots in the matrix have been filled or all jobs have been

sequenced.

Q.no 3-

Ans -

Item	1	2	3	4	5
Chocolate Mint	30	18	26	17	15
Peanut Butter	23	22	32	25	30
Short Bread	17	31	24	22	29
Fudge Delight	28	19	13	18	23
Macarooons	23	14	16	20	27

Matrix :

30	18	26	17	15
23	22	32	25	30
17	31	24	22	29
28	19	12	18	23
23	14	16	20	27

15	3	11	2	0
1	0	10	3	8
0	14	7	5	12
15	6	0	5	10
9	0	2	6	13

Crosses line not equal to order of matrix so,

15	3	11	0	0
1	0	10	1	8
0	14	7	3	12
15	6	0	3	10
9	0	2	4	13

                                                

15	3	11	0	0
0	0	10	0	7
0	15	7	3	12
15	7	0	3	10
9	0	2	4	13

Item
Chocolate Mint	5
Peanut Butter	4
Short Bread	1
Fudge Delight	3
Macarooons	2

Q. no -4

Answer –

Product	A	B	C	D	E
1	17	10	15	16	20
2	12	9	16	9	14
3	11	16	14	15	12
4	14	10	10	18	17
5	13	12	9	15	11

Matrix :

3	10	5	4	0
8	11	4	11	6
9	4	6	5	8
6	10	10	2	3
7	8	11	5	9

3	10	5	4	0
4	7	0	7	2
5	0	2	1	4
4	8	8	0	1
2	3	6	0	4

A	B	C	D	E
1	10	5	4	0
2	7	0	7	2
3	0	2	1	4
2	8	8	0	1
0	3	6	0	4

E	1
C	2
B	3
D	4
A	5