The Impact of Production Planning and Control on a Manufacturing Process A Case Study of Nigeria Bottling Company Aba Abia State

The Impact of Production Planning and Control on a Manufacturing Process

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ACKNOWLEDGEMENT

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The Impact of Production Planning and Control on a Manufacturing Process (A Case Study of Nigeria Bottling Company Aba, Abia State)

TABLE OF CONTENTS

PRELIMINARY PAGES

CHAPTER ONE

1.0 Introduction

  • 1.1 Background of the Study
  • 1.2 Statement of the Problem
  • 1.3 The Objectives of the Study.
  • 1.4 Research Questions
  • 1.5 Statement of Hypotheses
  • 1.6 Significance of the Study
  • 1.7 Scope/Delimitation of the Study/Imitation of the Study
  • 1.8 Definition of Terms

CHAPTER TWO

2.0 Literature Review

  • 2.1 The Historical Background
  • 2.2 The Theoretical Framework
  • 2.2.1 Production Planning
  • 2.2.2 Production Control
  • 2.2.3 Relevant Models/System
  • 2.3 Further Review of Literature
  • 2.3 Summary

CHAPTER THREE

Research Design / Methodology

  • 3.1 The Population Characteristics
  • 3.2 Sample Size
  • 3.3 The Sampling Technique Used In the Study
  • 3.4 Data Collection Instruments
  • 3.5 The Administration of Data Collection Instrument
  • 3.6 Validity of Data Collections and Reliability of the Instruments
  • 3.7 Statistical Tools Used For Data Analysis

CHAPTER FOUR

4.0 Presentation and Analysis of Data

  • 4.1 Respondents Characteristics and Classification
  • 4.2 Presentation and Analysis of Data According To Research Question
  • 4.3 Presentation and Analysis of Data According To Test of Hypothesis
  • 4.4 Discussion of Findings/Results

CHAPTER FIVE

5.0 Summary of Findings, Conclusion and Recommendation.

  • 5.1 Summary of Findings
  • 5.2 Conclusion
  • 5.3 Recommendation
  • BIBLIOGRAPHY
  • APPENDIX

ABSTRACT

The research work is to determine the Impact of Production Planning and Control in a manufacturing process. The Nigeria Bottling company Aba plant has been chosen as questionnaire and personal interview were use for collection of data. Research Question were made and two hypotheses were formulated to determine whether poor scheduling has any effect on the productivity of a manufacturing firm and also to know if there are rules for job processing in a manufacturing firm. Chi-square was used to test the hypothesis at 0.05 level of significant. The major findings of the study were that firm reviews their production plan and budget on quarterly basis so as to take into consideration the major season of the year. The analysis of variance by the production department through production process helps the firm to discover areas of short coming in production process. It was concluded that profitability and efficiency will be improved based on a production department through production budget in order to ensure minimization of cost so as to meet customer satisfaction and profit maximization.

The Impact of Production Planning and Control on a Manufacturing Process (A Case Study of Nigeria Bottling Company Aba, Abia State)

CHAPTER ONE

1.0 Introduction

1.1 Background Of The Study

Production planning deals with the determination, acquisition and arrangement of all facilities necessary for future manufacturing operations. The process involves also the allocation and scheduling of the resources to produce the desired goods and services in the required amounts at minimum total cost (that is, determining start, completion and delivery time) machine loading and also storage and handling items.

Effective production planning and control depends on information, meaning that production planning should take awareness of change in both the environment and within the organization. This is because changes in the environment impose change in the organization.

An effective production planning and control should know at any point in time the following questions:

  1. How work is done?
  2. Which machines are being used?
  3. How much labor is available?
  4. What raw materials and other inputs are currently in the stock, interruption may result from none or late delivery of materials, Machine breakdown, strikes and staff lateness due to public transport difficulties.

Breakdown in communication between the shop floor and the controlling unit will delay product. This has to be a continuous flow of information on workload, raw material availabilities and maintenance activities. Activities relevant to production includes design specification of dimensions, materials inputs and quality, ensuring the compatibility of one component with the others, description, issuing detailed instruction to supervisors, inspections, quality control, packaging, loading and dispatch.

Therefore this study explain why Nigerians firm fail to follow the rule of production planning and control. And also to know what manufacturing firms encounter in their attempt to carry out their production planning and control.

The firms that does not plan and control their production can be faced with the following problems:

  1. Inadequate sources of raw material
  2. Shortage of labor force
  3. Breakdown in machines used in the organization.
  4. Communications breakdown.

1.2 Statement Of The Problem

Production planning is subject to complex movement of items between work unit and operations, and it is easy for batches mistakenly to be broken up, machine loading can be complicated, also further difficulties that affect production planning and control are

  1. It might not be possible to avoid particular batches lying around for long periods between operations.
  2. Materials can fail to arrive at specific work points preventing the processing of work in progress and causing great descriptions to the entire system.
  3. Extensive documentation movement of batches around a factory may be required.
  4. Frequent movement of goods and material creates the need for the storage of items in many places and of many places and of many times during the production process.
  5. Coupling with a breakdown in the system this will cause to operate in its entirely following just a minor hold-up. Input materials will have to be put into storage while the stoppage is sorted out.
  6. Arranging the housing of the flow of output, especially when customers demand is low.

When batches planning for continuous flow of production is perhaps easier than that of items involved because of less detailed, scheduling (and associated paper work) is required. There is a single low of work through the system, changes to which after simple to implement on the other hand, planning for continuous production is inflexible in that labour and other resources cannot readily by re-delayed among difference machines in the event of a breakdown.

1.3 The Objectives Of The Study.

  1. To determine the effects of poor scheduling in meeting jobs completion times.
  2. To examine the rules adopted in job loading and their impact on job flows.
  3. To identify the specific routine procedures adopted by the firm and the overall impact on production process.
  4. To investigate whether the system of production planning and control is widely practiced among Nigerian firms.

1.4 Research Questions

  1. Does poor scheduling has any effect on the productivity of manufacturing firms?
  2. Are there rules for job loading in manufacturing firms?
  3. Are there steps involved in the overall impact of production process?
  4. Is the system of production planning effective in the Nigeria manufacturing firms?

1.5 Statement Of Hypotheses

Hypothesis I
  • Ho: The poor scheduling has no significant effect on the productivity of the manufacturing firms.
  • Hi: The poor scheduling has significant effect on the productivity of the manufacturing firms.
Hypothesis II
  • Ho: There is no rule for job loading in manufacturing firms.
  • Hi: There is rule for job loading in a manufacturing firm.

1.6 Significance Of The Study.

The significant of this study is hopefully believe to be a useful and unavoidable guide for future decision makers and serve as a bench mark for future research students and other entrepreneur in the field production planning and control.

It will also be beneficial to business, organization etc. In restructuring future planning and control in production aspect. This work will also enhance the effectiveness and efficiency of manufacturing firms, in other to meet their customer’s needs and demands.

This work will also be of benefit to recommend way through which the organization could reduce production cost to its best level in other to achieve its desired profit level.

1.7 Scope, Delimitation and Limitation Of The Study

This research work is an indebt on production planning and control impact in a manufacturing firm, using Nigeria Bottling Company Aba, as a case study.

The Nigeria Bottling Company Aba

This study will cover the entire production planning and control departments. The various sub-sections in the department shall from nucleus of the study and all their subordinates that are related.

The limitation of the study is within the reach of the selected case study due to some factors, the factors are as follow lack of sufficient finance, the work were limited to some extent because of poor finance and high cost of transport, there was no time to carry out all the research work as such. The fact were not gotten as at when needed.

1.8 Definition Of Terms

Production:

This is the process of co-coordinating man, materials and machine to create physical goods and services that will satisfy human wants and needs.

Production Planning:

This is the regulation, coordination and control of production facilities so as to meet a set delivery data at a reasonable cost.

Production Control:

This is the function of directing or regulating the orderly movement of goods through the entire manufacturing cycle from the requisition of the raw materials to the delivery of the finished products to meet the objective of the customer services, minimum manufacturing efficiency.

Manufacturing Process:

It is defined as any organization or an arrangement that convert raw materials into finished products (input process and output process) of direct materials, direct labour and factor overhead cost that have been accumulated some natural classification and allocation so as to reject the cost involved in the production of an item.

Scheduling:

A scheduling is a program of activities to determine the production of a particular term of specific times, accompanied by list of priorities and contingencies for when things do not work it as intended.

Machine Loading:

Machine loading decision concerns which machine (or collection of machines) is to be used for which purpose and for which periods.

Capacity Planning:

This means relating to the forecast level of demand for its products consist and show how it was distributed and retrieve of the instrument.

…

CHAPTER TWO

2.0 Literature Review

2.1 Introduction

This chapter focuses on the review of related literature. A literature review includes the current knowledge as well as theoretical and methodological contributions to a particular topic. It documents the state of the art with respect to the topic you are writing. It surveys the literature in the topic selected. In this research work the literature review includes the …

CHAPTER FIVE

5.0 Summary Of Findings, Conclusion And Recommendation.

5.1 Summary Of Findings.

The study revealed that effective production planning and control depends on information, meaning that production planning should take cognizance of change in both the environment and within organization. This is because change in the organization, likewise change in the production process.

Also an effective production planning and control should give clear direction of the work process from the beginning to the end in the following manner.

  1. How the work is being done?
  2. Which machine is being used?
  3. What raw material and other inputs are currently in the stock, interruption may result from none or late delivery of materials, machine break down and strikes.

While in chapter two the historical overview and theoretical foundation were dealt with. It also highlighted the contribution of some scholars on the topic like, Ejiofor (1989) who defines production planning as a process by which goods or services are created that is production is the process by which a set of desired outputs. Clearly the inputs and conversion process depends on the desired output.

Egolum and Okenwa (1999) opined the main purpose of production planning as to satisfy customer’s delivery by arranging the sequence of p[production activities in a manner of that pose little or no friction, and the main objectives is to provide information services for controlling and distribution of product.

While Agu (2000) highlight some the characteristics of production planning it include acceptance, adaptive to change, easy to understand and monitoring.

Nwachukwu (1988) also highlight some conditions that organization should follow to achieve effective control that is exception principle, timeliness, feedback and economy.

Finally, chapter four focused on the presentation of the analysis, in testing of hypothesis chi-square was used which the significant effect on the productivity of the manufacturing firms as show in hypothesis I and hypothesis II also proof that there are rules job processing in a manufacturing firms.

So the two result findings were in agreement due to the study environment used (manufacturing) and principles of management adopted.

5.2 Conclusion

Based on the findings of the study the following conclusions were made;

  1. Since production planning and control was best to recommend for efficiency in any manufacturing firm especially for the future operation of the company.
  2. Having made the basic assumptions that profitability and efficiency would be improved based on efficient production planning and control, use of this information would find it valuable in firms that falls under this category.
  3. The importance of subject matter should therefore be made known to business enterprises and economically rational industrialists to ensure better returns on their investments.
  4. Essentially this could be achieved through food production planning and control which will act as accidence of satisfaction of work well done by workers.

5.3 Recommendation

Going by the findings so far, the following recommendation will go a long way in helping the organization and manufacturing firms.

  1. They should establish a good and healthy working environment for the workers to enhance effectiveness and efficiency.
  2. The management should also note that it is not only equipment and building in production needs maintenance. Human facilities in the production system as well need effective and efficient maintenance.
  3. To improve on its performance through a well establishment of effective and efficient maintenance.
  4. To ensure that adequate care and through supervision takes place especially during manufacturing process.
  5. To make sure that all unavoidable deviation are corrected so as to meet the objective of production in the organization.
  6. There should be a room for periodic, job training for the workers in the production department to avoid the use of outdated method in manufacturing.
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