Table Of ContentProduction Planning and Control
Production Planning
and Control
A Comprehensive Approach
D.R. Kiran
Production Planning and Control
Production Planning
and Control
A Comprehensive Approach
D.R. Kiran
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About the author
Professor D. R. Kiran, B.Sc., B.E., M.Sc. (Eng.),
(Ph.D.), FIE(I), FIIIE, FIIProdE, FIIPlantE, FITTE,
FISNT, has a rich practical experience of 40 years
both in industry and academy. Starting his career in
1968 with Larsen & Toubro, he held top positions
including World Bank adviser/instructor for
Transport Managers in Tanzania, planning manager
of Rallifan (CF division), and was the principal of a
Chennai-based engineering college. He was in the
doctors’ panel for a Ph.D. student in2008.
In recognition of his services in the field of engi-
neering education, Professor Kiran was presented with the coveted Bharat
Excellence Award and Gold Medal for Excellence in Education in New
Delhi in 2006. He is listed as an International Expert in Industrial
Engineering and Management in the International Directory of Experts and
Expertise. He is nominated for the post of Honorary Deputy Director
General in India for the International Biographical Center.
During the 1980s, he was introduced to Dr. Julius Nyerere, the then-
president of Tanzania as a pioneer of work study in that country. He was one
of a few nonpolitical foreigners to be interviewed by the government news-
paper ofTanzania.
He started his academic career in 1979 and taught subjects like produc-
tion planning and control, total quality management, professional ethics and
maintenanceengineering management and at the B.E. level.
He was responsible for the establishments of many student chapters for
IIProdE and NIQR. His active participation in these activities and his experi-
ence as the planning manager of Rallifan and the National Bicycle
Company, where he was overall in charge of the production planning and
control (PP&C) department, provided him with the inspiration for planning
for a comprehensive book on production planning and control, providing
several casestudies onkeytopicsoutofhis richexperience. This isexpected
to beof immense help tothe students aswell as the practicing engineers.
His career as an industrial engineer and as planning manager, heading the
functionofPP&C at Rallifanand National Bicycle Co. gave him anopportu-
nity to introduce several systems and procedures in production management,
xxix
xxx Abouttheauthor
and the absence of a comprehensive Indian book with case studies motivated
himtoauthor thisbook,ProductionPlanningandControl:AComprehensive
Approach,whichishisfourthtextbookforengineeringstudents.
Earlier he has authored three engineering textbooks both at BE and PG
levels, the latter two published in the United States by Elsevier and Taylor&
Francis and which were launched successfully inBoston:
ü Professional Ethics and Human Values, published by McGraw Hill
Education, India
ü MaintenanceEngineering and Management:Precepts and Practices
ü Total Quality Management, Key Conceptsand Case Studies
He has published over 23 papers in Indian and foreign journals as well as
in conference proceedings. He was the organizing secretary for the success-
ful 29th Production Convention of the Institution of Engineers held in
August 2014. He is widely traveled, having visited over 30 countries, and is
a philanthropist. Having taught engineering students for over 3 decades, he
demonstrated his love for the student community by donating for the annual
best student awards at IE(I),ISNT, NIQR, and at Venkateswara Vidhyalaya.
Preface
Productionplanningandcontrol(PP&C)isakeyindustrialengineeringfunc-
tion for the manufacturing company whatever may be the fields of operation,
embodying techniques and tools each of which could form a topic by itself.
To comprehend these techniques and topics, it is essential to have basic
knowledgeoftheproductionfunctionsandtheirscope.Thisbookisprepared
in such a manner that even those who do not have much exposure to the
function of production planning would be able to comprehend them as they
are related toindustrialengineering.
PP&C function is a cross function, coordinating several specialized sub-
jects related to manufacture. While all aspects of PP&C function are dis-
cussed in this book, it would be beneficial to the students if they refer to
related subjects like quality management, operations management, mainte-
nance engineering, operationsresearch, etc.
As the planning manager at Rallifan, heading the PP&C department, the
author had the opportunity to introduce several PP&C systems and formats,
and with that experience, he was responsible for introducing similar systems
and formats at Tanzania’s National Bicycle Company right from its project
stage. This experience has been fully utilized in this book on the basics of
production planning. With all the case studies, this book is expected to be of
immense help not only to the engineering students but also to practicing
engineers who wanttodeveloptheir career on productionmanagement.
Though several books on PP&C or operations management are available,
there are very few that deal with all related aspects of PP&C, both in prac-
tice as well as prescribed in university syllabi worldwide. In view of this,
syllabi of several Indian and foreign universities on the subjects of PP&C
and operations management were referred to, and almost all the topics speci-
fied in these syllabi are included in this book, giving detailed explanations.
All these syllabi are cited as anappendixin thisbook.
Special importance is given to the fundamentals of statistics, so that the
reader is fully equipped to understand better the vital topic of forecasting,
which has a high bearing in statistics. Besides, exclusive chapters are
devoted on related topics like plant layout, scientific inventory control, criti-
cal path method, theory of constraints, etc. A unique feature of this book is
that two chapters are devoted to explain the fundamentals of Industry 4.0
and the Internet of things, which are the latest buzzwords reflecting
xxxi
xxxii Preface
advancement in manufacturing technology. This book is thus aptly titled
ProductionPlanning and Control: A Comprehensive Approach.
Another feature of this book is that besides the syllabi, the university
questions from several Indian and foreign universities are compiled, classi-
fied chapter-wise, and given at the end of each chapter as criteria questions,
indicating the relevant paragraph number as a clue. This is expected to make
the book highly examination oriented for the student besides being practical
oriented tothe PPC engineer.
D.R. Kiran
