MINIMIZING DEFECTIVE PRODUCT THROUGH EFFECTIVE PRODUCTION PLANNING AND CONTROL IN DEFENCE INDUSTRIES CORPORATION OF NIGERIA
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MINIMIZING DEFECTIVE
PRODUCT THROUGH EFFECTIVE PRODUCTION PLANNING AND CONTROL IN DEFENCE INDUSTRIES
CORPORATION OF NIGERIA
ABSTRACT
This research work examine production planning and control as
a tool for minimizing defective products through effective production planning
and control in Defence Industries Corporation of Nigeria (DICON), Kakuri
Kaduna. Hence the scope of the research cover every activity which has to do
with production planning and control. The work covers statement of the general
problems, research objectives, scope of the study, significance of the study
and limitation of the study. Also diverse view of authors on production
planning and control and other related areas in review. The research work
employs the descriptive method for the purpose of an in-depth investigation. A
sample size of 70 respondents was selected from the total population of 180
staff, questionnaire were administered to them, oral and verbal interview as
well as obtaining information. Hypothesis H0 and H1 formulated on using
effective production planning and control to minimize defective product in
production performance. Date collected were presented and daily analyzed in
tabular format using percentages, other findings of the studying centered on
the required raw materials used by the organization but sourced outside the
country, government policies such as hinge tax payments, customers and excise
charges contributes to high production cost with locally sourced raw materials
not maintaining a stable price from time to time with future plans having
limitation due to some government regulations, economic downs turn,
environmental factors technological changes, competitors actions. The study
also brought to the fore the importance of production planning and control in
the role of forecasting in production and operation management. Finally based
on the findings a number of quality recommendation were offered to the
organization to embrace in raw materials sourcing using alternative means i.e.
research and development department, the complete computerization of the
control system and other key system should be pursued effectively.
CHAPTER ONE
1.1 BACKGROUND OF
THE STUDY
Production Planning and Control provides the foundation for
any effective production management in every organization or manufacturing
sector by minimizing defective products is very vital issue to a production
managers.
To guarantee effective material flow Production Planning and
Control represents the beating heart of any manufacturing process. Production
Planning and Control purpose is to minimize production time and costs,
efficiently organize the use of resources and maximize efficiency in the work place.
Production Planning as defined by Digreens (2009, pg. 21) “is
a set of function concerned with the effective utilization of limited resources
(such as raw materials, manpower, machinery etc.) and the management of
materials flow through these resources, so as to satisfy customer demands and
create profit.
As can be seen in other related field of management,
Production Planning and Control plays the primary functions of the production
management and operations.
This has prompted this research work to look at Production
Planning and Control as a tool for minimizing defective product in
manufacturing industries of Nigeria economy as exemplified by Defence
Industries Corporation of Nigeria Kakuri, Kaduna. Production is the central
focus of any manufacturing concern. It is the platform where the real mix takes
place i.e. the conversion of raw materials (in-put, starters) into completed or
finished products (output) after a well planned logical form or process
production planning incorporate a multiplicity of production elements, ranging
from the every day activities of staff to the ability to realize accurate
delivery times for the customers.
Modern and improve production is complex hence
technologically related operations and administrative activities must be planned
carefully to make account and benefits. With an effective production planning
cooperation at its nucleus, any form of manufacturing process has the
capability of exploit its full potential.
In Production Planning, it not only involves the type of operation
to be used but also the order of these operations as well as time which the
operation should take and how it should be properly and effectively laid out.
There are different function performed by Production Planning
and Control Department of an organization. Procedures may also vary; all the
production planning and control department are essentially expected to perform
the following functions:
According to Buffa, E.S, Modern Management, New Delhi: Willy
1988 “Production Planning may be defined as the technique of foreseeing every
step in a long series of separate operations, each step to be taken at the
right time and in the right place and each operation to be performed in maximum
efficiency.” It helps entrepreneur to work out the quantity of material,
manpower, machine and money requires for producing predetermined level of
output in a given period of time.
Routing: Under this, the operations their path and sequence
are established. To perform these operations, the proper class of machines and
personnel required are also worked out. The main aim of routing is to determine
the best and cheapest sequence and to ensure that this sequence is strictly
followed.
Routine procedure involves following different activities:
1. An
analysis of the article to determine what to make and what to buy.
2. To
determine the quality and type of material.
3.
Determining the manufacturing operations and their sequence.
4. A
determination of lot sizes
5.
Determination of scrap factors
6. An
analysis of cost of the article
7.
Organization of production control firm
Scheduling: It means working out of time that should be
required to perform each operation and also the time necessary to perform the
entire series as routed, making allowance for all factors concerned. It mainly
concerns with time element and priorities of a job. The pattern of scheduling
differs from one another which is listed below:
a) Production
Schedule: The main aim is to schedule that amount of work which can easily be
handled by plant and equipment without inference. Its not independent decision
as it takes into account the following factors.
i) Physical
plant facilities of the type required to process the material being scheduled.
ii) Personnel
who possess the desired skills and experience to operate the equipment and
perform the type of involved.
iii) Necessary
material and purchased parts.
b) Master
Schedule: Scheduling usually start with preparation of master schedule which is
weekly or monthly break-down of the production requirement for each, product
for a definite time period; by having this as a running record of total
production requirement. This forms a base for all subsequent scheduling
activities. A master schedule is followed by operator schedule which fixes
total time required to do a piece of work with a given machine or which shows
the time required to do each detailed operation of a given job with a given
machine or process.
c) Manufacturing Schedule: It is prepared on
the basis of type of manufacturing process involved. It is very useful where
single or a few product are manufactured repeatedly at regular interval. Thus
it would show the required quality of each product and sequence in which the
same to be operated.
d) Scheduling
of Job Order Manufacturing: Scheduling acquires greater importance in job
ordering manufacturing. This will enable the speedy execution of job at each
center point. It enables the foreman to see at a glance;
i) The total
load on any section
ii) The
operational sequence
iii) The stage,
which any job has reached
Loading: The next step is the execution of the schedule plan
as per the route chalked out, it includes the assignment of the work to the
operators at their machines or work places. So loading determines who will do
the work as routing determine where and scheduling determines when it shall be
done.
Production Control:
Samuel Elison (1994) in his book, Element of Production
Planning and Control, Bombay: Universal Book Co., 1985 says “Production control
is the process of planning production in advance of operation, establishing the
extract route of each individual item part or assembly, setting, starting and
finishing production and releasing the necessary order as well initiating the
necessary follow-up to have the smooth function to the enterprise.
Dispatching: Dispatching involves issue of production order
for starting the operation, necessary authority and confirmation is given for:
i) Movement
of materials to different work station
ii) Movement
of tools and fixtures necessary for each operation
iii) Beginning
of work on each operation
iv) Recording
if time and cost involved in each operation.
v) Movement
of work from one operation to another in accordance with the route sheet.
vi) Inspection
or supervision of work.
Dispatching is an important step as it translate production
plan into production.
Follow Up: Every production programme involve determination
of the progress of work, removing bottlenecks in the flow of work and ensuring
that the productive operation are taking place in accordance with the plans. It
spot delays or deviation from the production plans. It helps to reveal defects
in routing and scheduling, misunderstanding or orders and instruction, under
loading or over loading of work etc.
Inspection: This is mainly the quality of goods, it can be
required as effective agency of production control.
Corrective Measure: Corrective action may involve any of
those activities of adjusting the route, rescheduling of work changing the work
loads, repairs and maintenance of machinery or equipment, control over
inventories of the cause of deviation in the poor performance of the employees.
Certainly personnel decisions like training, transfers, demotion etc. may have
to be taken alternative methods may be suggested to handle peak loads. The
following are required to be able to achieve the activities successfully:
i) Sales or
contract programmes
ii) Approval
of design for manufacturers
iii) Jigs and
fixture tools for manufacturer
iv) Rate fixing
and time study – work study
v) Estimate
of costs – labour, overhead experience etc.
vi) Routine and
machine allocation
vii) Amount of
inspection required and necessary
viii)
Labour/workforce required e.g. skilled or unskilled
ix) Report
writing i.e. finding reported for appropriate action
1.2 STATEMENT OF
RESEARCH PROBLEM
For a manufacturing organization and indeed any other
organization besides the general planning and control planning, control of
materials is particularly very crucial for its survival hence effective
producing planning and control is necessary in every organization.
The success of our present day industries depends on how to
effectively utilize and to enhance growth and development and sustain for
better industrialization.
Therefore, this research work is concerned with identifying
the way in which defective product can be minimized through effective
production planning and control in Defence Indus tries Corporation of Nigeria.
To this end, the following questions occupy our mind before
the research as problem generally associated on what roel does the choice of
production planning and control plays in a Defence industries.
The researcher wants to know why production planning and
control is vital and useful in minimizing defective products in Defence
Industries.
While there is not standard system in production planning and
control which can be universally recommended, even production planning and
control system must be designed to meet the particular needs and concern of the
manufacturing organization.
1.3 OBJECTIVE OF
THE STUDY
The importance of production planning and control motivated
me to undertake a study of how the principle and techniques of production
planning and control are applied in defence industries corporation of Nigeria
(DICON), Kakuri Kaduna.
However, the primary concern of this research work is to
investigate.
a) The tool
to minimize defective product in Defence Industries that deals with the production
of arms and ammunition.
b) The study
is also aimed at examining the effectiveness of the application of production
planning and control in today’s manufacturing for the growth of the
organization and at the same time provide useful suggestion to the identified
problems by advising the management all cost associated and increase efficiency
in the organization as a whole.
c) The
factors influencing the choice of production.
d) Various
factors, which are crucial for designing the production.
It is hoped that, this objectives when attain will be
tremendous benefit to the Defence Industries Corporation of Nigeria (DICON) and
Nigeria in general.
1.4 SIGNIFICANCE
OF THE STUDY
This study will be of great significance in that it seeks to
emphasize on:
a) How the
principle and technique of production
planning and control has been practiced as DICON ordnance factory complex,
Kakuri Kaduna.
b) The entire
process involve that make production of each arm and ammunition possible from
the start of production, steps it passes through and detail of the whole
process.
c) It will
help in broadening the academic horizon of the researcher.
Finally, it is hoped that the work will serve as a reference
guide to students and scholars who ought to use it.
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