1.

Explain the importance of PPC department in a typical production system.

2. Write about the Elements of production control
3. Explain various benefits of forecasting methods?
4. A computer software firm has experienced the following demand for its
“Personal Finance” software package

Period 1 2 3 4 5 6 7 8

Units 56 61 55 70 66 65 72 75

i. Develop an exponential smoothing forecast using α=0.4 and an

adjusted exponential smoothing using α=0.4 and β=0.20
ii. Compare the accuracy of two forecasts using MAD and cumulative
error
5. Explain P and Q systems of controlling the inventories with neat diagrams
6. The annual demand for an automobile component is 36000 units. The
carrying cost is Rs. 0.50/unit/year, the ordering cost is Rs.25.00 per order
and the shortage cost is Rs.15.00/unit/year. Find the optimal values of the
following:
i. Economic Ordering Quantity
ii. Maximum inventory
iii. Maximum shortage quantity
iv. Cycle time
7. Explain the logic of Material Requirement Planning System? Explain with
example
8. What are the important factors that affecting routing procedure.
9. Explain bills of material importance in production control. How does it help
in assembly production?
10.Categorize various scheduling techniques and list significance of each
method briefly
11.A house painting contractor has five houses to paint. Following are the
estimated times required to paint each house and due date for completion.

House Estimated Due date

Time (days)

 A 2.5 8

B 4 10

C 3 7

D 5 14

E 2 16

Use the Shortest Processing Time rule to sequence the five jobs Compute
average flow time and average tardiness per job using this sequence
12.What is expediting and explain about the duties of expediter?
13.The Company needs to produce 4000 boxes of blocks per 40 hour week to
meet upcoming holiday demand. The process of making blocks can be
broken down into six work elements. The precedence and time
requirements for each element are as follows. a) Draw precedence diagram
for the production process b) Determine minimum number of work stations
and c) balance efficiency.

Work Precedence Performance

element time (min)

A - 0.1

B A 0.4

C A 0.5

D - 0.2

E C, D 0.6

F B, E 0.4

14.What is dispatching? What is its significance? Enumerate its advantages in

production control.
15.Explain about the applications of computer in production planning and
control.
16. Explain the scope of production planning and control. Explain the boundaries with the
help of organization chart
17. Give the internal organization of PPC department and Compare job shop and Batch type
production systems
18. List out various qualitative techniques for forecasting
19. A manufacturing company has monthly demand for one of its products as follows:
Month Feb Mar Apr May Jun July Aug Sept
Demand 520 490 550 580 600 420 510 610
i. Develop a three period moving average forecast
ii. Develop three period weighted moving average forecast with weights of 0.50, 0.30
and 0.20 for the most recent demand values.
20. Define inventory? Explain various functions of inventory
21. Alpha industry estimates that it will sell 12000 units of its product for the forthcoming
year. The ordering cost is Rs. 100 per order and the carrying cost per unit per year is 20%
of the purchase price per unit. The purchase price per unit is Rs.50.Find
a. Economic Order quantity
b. No. Of orders per year
c. Time between successive orders.
22. Explain the various steps of Line of Balance technique?
23. What is ERP system? Explain any three segments of ERP system
24. Define routing & its significance. Explain about the important components of
25. routing sheets?
26. Explain about difference with loading in detail?
27. Explain about Scheduling techniques in brief?
28. Write about standard scheduling policies in detail?
29. Explain various types of expediting procedures
30. What is difference between an aggregate plan and a master production schedule?
31. Describe advantages & disadvantages of dispatching jobs all at once and operation by
operation.
32. Explain about the types of follow up in detail?
33. Explain various objectives of Production Planning Control (PPC) department.
34. Discuss different types of production systems with suitable examples?
35. List out various quantitative techniques for forecasting?
36. Forecast the production for next two years when the production quantity for last ten years
is as follows: 200,225,235,240,255,260,265,275,270,271. Use the following methods and
comment on results
a. Simple average
b. Moving average (3 years and 5 years)
c. Exponential smoothing for α=0.3 and 0.7
37. Explain various costs associated with inventory.
38. If a product is to be manufactured within the company, the details are as follows:
Annual demand rate, =24000 units
Production rate, =48000 units
Setup cost, =Rs. 200 per setup
Carrying cost,= Rs.20/unit/year.
Find the a) EOQ and b) Cycle time
Distinguish between Line Balancing and Line of Balance.
What are the reasons for scheduling? Explain how scheduling improves the process of
production control significantly.
39. Explain about steps involved in routing procedure?
40. Compare and contrast different scheduling policies.
41. David is an independent computer software consultant. After completing his most recent
project, he had five jobs awaiting completion. Following are the estimated work times
required to complete each job and due dates requested by customers
Job Processing Due date(days
time from present)
A 12 52
B 16 37
C 8 28
D 20 57
E 6 31

Construct job sequences using the Shortest Processing Time rule, Earliest Due
Date rule and Compute the average flow time.

42. List out various aspects of production control? Explain any three aspects in detail.
43. What are the advantages and disadvantages of using a chase demand strategy for
developing an aggregate planning?
44. Compare & contrast dispatching centralized control VS Dispatching decentralized control
45. Explain various activities of dispatcher
46. Explain various functions of Production Planning Control (PPC) department.
47. What are the advantages of production planning and control and Explain various
principles and procedures of production control?
48. What is forecasting and Explain the importance of forecasting?
49. The cost per standardized long distance phone call has been decreasing over time. Using
the following data for the last 8 years
Year 1 2 3 4 5 6 7 8
Standardized 3.25 3.05 2.98 2.93 2.91 2.58 2.44 2.37
Cost

a. Use linear regression to compute an expression for cost as a linear function of time
b. Using above equation, predict the standardized cost for year 10
50. Compare VED analysis with ABC analysis.
51. A company requires 10000 units of an item per annum. The cost of ordering is rs.100 per
order. The inventory carrying cost is 20%. The unit price of the item is Rs.10. Calculate
a) the economic order quantity b) Optimal total annual cost c) time between the orders.
52. Explain about the MRP II system in detail?
53. Explain the role of bills of material with the help of block diagram
54. What is the significance of loading? Explain with the help of machine load record.
55. List out various scheduling rules and Explain at least three of them
56. At an electronics repair shop all items are first diagnosed by an expert technician. He
estimates the amount of repair work required and assigns it to a second technician for
completion. The second technician has five jobs awaiting work with the expected work
time required and due date listed below
Job Expected Due date
repair time
A 5.5 8
B 6 16
C 3.5 16
 D 5 20
E 4 24
Construct job sequences using the Critical ratio rule, and Slack Time Remaining rule
and Compute the average flow time
57. What is aggregate planning and Explain various objectives of aggregate planning
58. List out various heuristics for line balancing problem. Explain any one heuristic in detail
with example
59. What is material follow up? What is the role of purchase department in material follow
up?
60. List out various forms raised by dispatcher? Explain any three with neat sketch
61. Define and explain the role of production planning and control in an organization.
62. Explain different types of production briefly.
63. Define forecasting. Discuss the importance of demand forecasting in an industry.
64. Distinguish between the qualitative and quantitative methods of sales forecasting
techniques.
65. What do you understand by the term ‘Economic Order Quantity’? On what factors does it
depend explain.
66. Explain about various inventory costs.
67. Explain various steps of line of balancing technique.
68. Explain the concept of MRP system.
69. What is routing? What are the factors responsible for proper routing? Explain.
70. What is Gantt chart? Discuss the use of Gantt chart for scheduling purpose with an
example.
71. What is aggregate planning? What are its objectives? What is the need for aggregate
planning and explain various steps in aggregate planning?
72. What is dispatching? What are the various activities of a dispatcher?
73. Explain the applications of computer in PPC.
74. Explain the different functions of production planning and control.
75. Write any sven differences between job shop, batch type and continuous production
systems.
76. List and explain the general principles of forecasting.
77. Explain about the method of least squares. Write its merits and demerits.
78. Reliance Ltd. has achieved the exports during 1992-93 to 1996-97 exhibited in the
following table. Compute the exports during 2001 -2002 by the method of least squares.
Year 1992-93 1993-94 1994-95 1995-96 1996-97
Exports(crores) 1.49 1.24 1.69 1.70 3.11
79. Explain the functions of inventory management.
80. Write any seven differences between P and Q systems.
81. Explain about the concept of ERP system.
82. Distinguish between route card and route sheet.
83. What do you understand by BOM? Why they are prepared and explain with an example.
84. Explain the objectives of scheduling.
85. Explain Johnson’s rule of scheduling the sequence of jobs.
86. What is aggregate planning? What are the different approaches to aggregate planning?
Explain.
87. What is line balancing? Explain line balancing procedure.
88. What is dispatching? Explain the dispatching procedure in detail.
89. What is follow up and explain various types of follow up briefly.
90. Explain the objectives of production planning and control.
91. Explain the internal organization of PPC department.
92. ‘Forecasting is essential not only in business but in our daily life also’- support the
statement with brief explanation.
93. Explain about method of least square and exponential smoothing method.
94. Explain about ABC and VED analysis.
95. Explain the different functions of inventory.
96. Explain about inputs and outputs of MRP system.
97. What is route sheet? How are they prepared and give factors affecting routing procedure.
98. What is scheduling? Explain different scheduling techniques and their significance.
99. Explain the concept of chase planning.
100. What is expediting and explain its importance in production planning.
101. Write any four advantages and disadvantages of dispatching–centralized.
102. Write any four advantages and disadvantages of dispatching–decentralized.
103. Explain the role of computers in production planning and control.
104. Explain the basic elements of production control system.
105. Discuss the place of PPC department in the organization set up.
106. What are different types of forecasting? Explain their significance, merits and
demerits.
107. Explain about fixed order quantity system and fixed order period system.
108. Explain about ABC and VED analysis.
109. Explain the techniques of Line of Balancing process.
110. Write any six differences between loading and scheduling.
111. Explain about the factors affecting the routing procedure briefly.
112. Explain about forward and backward scheduling.
113. Explain about scheduling using different scheduling norms.
114. The precedence and the time requirements for each element are shown in table. The
line operates for 7 hrs per day and an output of 550 units per day is desired.
a) Draw the precedence diagram for the production process.
b) Calculate i) cycle time and ii) Theoretical minimum number of workstations
required.
c) Group the tasks into number of workstations.
d) Calculate balance efficiency.
Work A B C D E F G
element
Precedence - A B C C D,E F
Time(min.) 0.65 0.40 0.30 0.20 0.45 0.40 0.30
115. Explain any eight applications of computer in PPC.
116. Explain the importance of a dispatcher in production and various activities of a
dispatcher.
117. What is job order production?
118. State the objectives of short term forecasting.
119. Give a short note of ABC analysis.
120. Define routing. List out limitations of routing.
121. What is scheduling? What are its objectives?
122. Discuss any four applications of computer in PPC.
123. Describe the functions of Production planning and control.
124. State the purpose of a manufacturing organization in an industry. Give a typical
organization structure of a manufacturing organization.
125. Describe ‘Exponential Smoothing Method’ of sales forecasting. State its advantages
and limitations.
126. Find the trend using least square method for the date below. Also estimate demand for
1984.
Year 1975 1976 1977 1978 1979 1980 1981
Demand in 85 75 80 72 65 60 55
1000 units
127. Explain the significance of EOQ formula. What are its Limitations?
128. What is meant by VED analysis? What is its significance?
129. Explain how the routing differs in job order, intermittent and continuous production
systems.
130. List out and explain the objectives of routing.
131. Following data is available for processing three orders: A, B and C. Order AJ712 was
received two days after receipt of order AJ600 and AJ720 was received one day after
receipt of order AJ712. One day is required for setting up and material handling between
each operation. Prepare a Gantt schedule chart. There are no machine restrictions.
Estimated time(days)
Operation No. Order No. Order No. AJ Order No. AJ
AJ712 720 600

10 7 8 3
20 5 2 5
30 3 4 5
40 2 - -
50 1 - -
60 1 - -
132. Explain about the dispatching procedure.
133. Explain the necessity of close control in dispatching activities?
134. What is batch production?
135. State the objectives of long term forecasting.
136. What is the importance of route sheet?
137. Describe master scheduling.
138. Discuss the advantages of decentralized dispatching.
139. Explain the relationship between ‘Production planning’ and ‘control’.
140. Describe the activities in follow up or control phase of PPC.
141. Forecast the demand for the following series by exponential smoothing method:
Period 1 2 3 4 5 6 7 8 9 10
Actual 10 12 8 11 9 10 15 14 16 15
Demand
142. Name and describe the various factors affecting sales forecasting.
143. How can load reports be used to develop material requirement plans?
144. Explain the factors affecting the inventory costs.
145. Explain the bill of material with design specification chart.
146. Define routing. Explain the routing procedure in brief.
147. A machine operator processes five types of products and must choose sequence for
them. The set-up cost per change (Rs.) depends on the products presently on the machine
and the set-up be made according to the following table. Changeovers from A to D and C
to E are not allowed. How should one sequence the products in order to have minimum
total set-up cost?
From To Product
Product A B C D E
A - 4 7 - 4
B 4 - 6 3 4
C 7 6 - 7 -
D 3 3 7 - 6
E 4 6 4 5 -
148. What is meant by Dispatching?
149. Explain the different types of follow ups?
150. Give a list of records maintained by Dispatching Department?
151. What is continuous production?
152. Describe moving average method.
153. What are the factors affecting routing procedure.
154. Describe production scheduling.
155. Discuss the advantages of centralized dispatching.
156. Describe in brief, planning in manufacture organization.
157. Define production planning. State its objectives. List the information required for
production planning.
158. State the advantages and limitations of sales forecasting.
159. Project the trend of sales for the next four years.
Year 1983 1984 1985 1986 1987
Sales in 120 140 150 170 190
Lakh
160. Explain the principles of MRP system.
161. Classify inventory models? Discuss briefly any one of them?
162. What do you meant by bill of material? Explain in detail.
163. Discuss different routing procedure.
164. For the following data, find the schedule that minimizes the mean flow time, if the
number of parallel machines is 2.
Job 1 2 3 4 5 6 7 8
Processing 4 6 3 7 2 1 5 9
Time (hr)
165. What is dispatching? State the various activities of dispatching in brief.
166. Name and describe the common forms used for dispatching.
167. What are the objectives of PPC.
168. Explain the objectives of forecasting.
169. Give a short note on Line of Balance.
170. What is the importance of loading?
171. What is the role of LOB in project scheduling?
172. Briefly explain dispatching rules.
173. State the advantages of better Production planning and control.
174. Name the various types of production systems. Describe the production system
suitable for job work.
175. Explain the importance of sales forecasting.
176. Describe ‘Least square method’ of sales forecasting with its advantages and
limitations.
177. Compare VED analysis with ABC analysis.
178. Explain the terminology involved in MRP system.
179. Describe route sheet with a suitable example.
180. Explain the importance of bill of material in production line.
181. A bomb squad faces a terrible situation that the members wish had never happened. A
terrorist has planted five bombs in an airport building, endangering lives and property.
 The squad has located all five bombs and must now proceed to dismantle them. Because
of limited staffing, the bombs can be dismantled only sequentially. Unfortunately, there is
not much time left and the squad must choose judiciously the order in which the bombs
will be dismantled. The following data represents a reliable estimate by the squad. What
sequence for dismantling the bombs would you recommend to the squad? What should be
the criterion that the squad optimizes?
Bomb 1 2 3 4 5
Time to dismantle (hours) 3 1 2 4 1
Time remaining before the bomb will 9 11.25 11 6 5
explode (hours)
List out and briefly explain the activities of dispatcher.
Explain the applications of computer in production planning and control.
Define continuous production system. Write any three differences between mass production
and flow production.
Write about moving average method.
Write any four benefits of MRP.
Write a short note on BOM.
Write a brief note on production scheduling.
What is follow up? State any three objectives.
Describe the functions of production planning and control in detail.
What is internal organization of a department? Explain it briefly by taking an example.
Describe ‘Least Square Method’ of sales forecasting with its advantages and limitations.
Forecast the demand for the following series by exponential smoothing method by taking α =
0.3 and 0.6
Period 1 2 3 4 5 6 7 8 9 10
Actual 10 12 8 11 9 10 15 14 16 15
demand
Define inventory. What are the various types of inventory? Why are they maintained?
A factory needs 36000 units annually of a component that cost Rs.2 per unit. Cost of each
order placing is Rs.25 and inventory carrying cost is Rs.10 per year.
(i) Find the economic lot size and the total inventory cost.
(ii) What is the time between placing of orders?
(iii) The supplier offers 2% discount if a single order is placed. Should
the company accept it?
Define routing and explain what are the factors affecting the routing procedure in detail.
Write any four differences between scheduling and loading.
Describe briefly the line of balance technique of project scheduling.
What is aggregate planning? Write its functions, merits and demerits.
What is dispatching? State various activities of a dispatcher.
Write any eight applications of computers in PPC.