Follow Up in Production Planning and Control

Introduction

Follow up is an essential component of production planning and control. It involves monitoring and ensuring that tasks and activities are progressing as planned, materials are available when needed, and quality standards are met. In this topic, we will explore the key concepts and principles of follow up, the types of follow up, expediting procedures, applications of computers in planning and control, typical problems and solutions, real-world applications, and the advantages and disadvantages of follow up.

Key Concepts and Principles of Follow Up

Definition of Follow Up

Follow up can be defined as the process of monitoring and tracking the progress of tasks, materials, and quality control measures to ensure that production activities are on schedule and meet the desired standards.

Types of Follow Up

There are three main types of follow up:

1. Progress Follow Up

Progress follow up involves monitoring the progress of tasks and activities to ensure that they are being completed as planned. It includes tracking the completion of milestones, identifying any delays or bottlenecks, and taking corrective actions to keep the production process on track.

1. Material Follow Up

Material follow up focuses on ensuring that the required materials are available when needed. It involves tracking the delivery of materials, coordinating with suppliers, and expediting the delivery process to avoid any delays in production.

1. Quality Follow Up

Quality follow up involves monitoring and ensuring that the desired quality standards are being met. It includes conducting inspections, implementing quality control measures, and taking corrective actions to address any quality issues.

Expediting Definition

Expediting refers to the process of accelerating or speeding up the production activities to meet the desired schedules or deadlines. It involves taking proactive measures to ensure that tasks and activities are completed on time.

Expediting Procedures

To effectively expedite production activities, the following procedures can be followed:

1. Identifying Critical Activities

Identify the critical activities that have the potential to cause delays or impact the overall production schedule. These activities should be closely monitored and given priority.

1. Setting Priorities

Set priorities based on the criticality of activities and the overall production schedule. Allocate resources and manpower accordingly to ensure that the most important tasks are completed first.

1. Monitoring Progress

Continuously monitor the progress of tasks and activities to identify any deviations from the planned schedule. Regularly update the production status and communicate any delays or issues to the relevant stakeholders.

1. Taking Corrective Actions

If any delays or issues are identified, take immediate corrective actions to address them. This may involve reallocating resources, adjusting schedules, or implementing alternative production methods.

Applications of Computers in Planning and Control

Computers play a crucial role in planning and control, including follow up. Some of the applications of computers in planning and control include:

1. Automated Follow Up Systems

Automated follow up systems use computer software to track and monitor the progress of tasks, materials, and quality control measures. These systems provide real-time updates and alerts, enabling timely interventions and corrective actions.

1. Real-time Monitoring and Reporting

Computers enable real-time monitoring and reporting of production activities. This allows managers and supervisors to have up-to-date information on the progress of tasks, identify any bottlenecks or delays, and make informed decisions to keep the production process on track.

1. Data Analysis and Decision Support

Computers can analyze large amounts of data related to production activities, materials, and quality control measures. This analysis helps in identifying patterns, trends, and areas for improvement. It also provides decision support by generating insights and recommendations for optimizing production processes.

Step-by-Step Walkthrough of Typical Problems and Solutions

Delayed Delivery of Materials

1. Identify the Cause of Delay

When there is a delay in the delivery of materials, it is important to identify the root cause of the delay. This could be due to issues with the supplier, transportation, or other external factors.

1. Communicate with Suppliers

Once the cause of the delay is identified, communicate with the suppliers to understand the situation and find a solution. This may involve renegotiating delivery dates, finding alternative suppliers, or expediting the delivery process.

1. Expedite Delivery

Take proactive measures to expedite the delivery of materials. This may include tracking the shipment, coordinating with logistics providers, or using alternative transportation methods.

Production Delays

1. Identify Bottlenecks in the Production Process

When there are delays in the production process, identify the bottlenecks or areas that are causing the delays. This could be due to resource constraints, equipment breakdowns, or inefficient workflows.

1. Allocate Resources to Speed up Production

Once the bottlenecks are identified, allocate additional resources or manpower to speed up the production process. This may involve hiring temporary workers, investing in additional equipment, or optimizing the workflow.

1. Monitor Progress and Adjust Schedules

Continuously monitor the progress of production activities and adjust schedules as needed. Regularly communicate with the production team to ensure that tasks are being completed on time and make any necessary adjustments to the production schedule.

Quality Issues

1. Identify the Root Cause of Quality Problems

When quality issues arise, it is important to identify the root cause of the problems. This could be due to issues with the raw materials, production processes, or equipment.

1. Implement Corrective Actions

Once the root cause is identified, implement corrective actions to address the quality problems. This may involve revising production processes, conducting additional inspections, or training the production team.

1. Monitor Quality Control Measures

Continuously monitor the effectiveness of quality control measures and make any necessary adjustments. Regularly conduct inspections and audits to ensure that the desired quality standards are being met.

Real-World Applications and Examples

Automotive Industry

In the automotive industry, follow up plays a crucial role in supply chain management and just-in-time manufacturing.

1. Follow Up in Supply Chain Management

Follow up is essential in managing the complex supply chain in the automotive industry. It involves tracking the delivery of materials, coordinating with suppliers, and ensuring that production activities are on schedule.

1. Expediting Procedures in Just-in-Time Manufacturing

Just-in-time manufacturing relies on efficient follow up and expediting procedures. The goal is to minimize inventory levels and ensure that materials are delivered just in time for production.

Construction Industry

In the construction industry, follow up is important for project management and on-time completion.

1. Follow Up in Project Management

Follow up is crucial in managing construction projects. It involves tracking the progress of tasks, coordinating with subcontractors, and ensuring that the project is completed within the specified timeline.

1. Expediting Procedures for On-time Completion

To ensure on-time completion of construction projects, expediting procedures are followed. This includes closely monitoring the progress, coordinating with suppliers, and taking proactive measures to address any delays.

Advantages and Disadvantages of Follow Up

Advantages

Follow up offers several advantages in production planning and control:

1. Improved Efficiency and Productivity

By closely monitoring the progress of tasks and activities, follow up helps identify any bottlenecks or delays. This allows for timely interventions and corrective actions, leading to improved efficiency and productivity.

1. Timely Delivery of Products

Follow up ensures that materials are available when needed and production activities are on schedule. This helps in ensuring timely delivery of products to customers.

1. Better Quality Control

By monitoring and implementing quality control measures, follow up helps in maintaining and improving the quality of products.

Disadvantages

Follow up also has some disadvantages that need to be considered:

1. Increased Administrative Workload

Follow up requires continuous monitoring, tracking, and reporting of production activities. This can increase the administrative workload for managers and supervisors.

1. Potential for Over-Expediting and Rushing

In an effort to meet deadlines, there is a risk of over-expediting or rushing production activities. This can compromise quality and lead to errors or rework.

1. Dependency on Suppliers and External Factors

Follow up relies on the timely delivery of materials and cooperation from suppliers. Any delays or issues with suppliers can impact the overall production schedule.

Summary

Follow up is an essential component of production planning and control. It involves monitoring and ensuring that tasks and activities are progressing as planned, materials are available when needed, and quality standards are met. There are three main types of follow up: progress follow up, material follow up, and quality follow up. Expediting is the process of accelerating production activities to meet schedules or deadlines. Computers play a crucial role in follow up, enabling automated systems, real-time monitoring, and data analysis. Typical problems in follow up include delayed delivery of materials, production delays, and quality issues, which can be addressed through proper identification and corrective actions. Follow up has real-world applications in industries such as automotive and construction. It offers advantages such as improved efficiency, timely delivery, and better quality control, but also has disadvantages such as increased administrative workload and dependency on suppliers and external factors.

Analogy

Imagine you are planning a dinner party. You have a list of tasks to complete, such as shopping for ingredients, preparing the food, and setting the table. Follow up in production planning and control is like continuously checking the progress of each task to ensure that everything is on track. You monitor the progress of the food preparation, check if all the ingredients are available, and make sure the table is set properly. If there are any delays or issues, you take corrective actions to ensure that the dinner party is a success.