TABLE OF CONTENTS
Title page - - - - - - - - - -
Declaration - - - - - - - - -
Approval page - - - - - - - - -
Dedication - - - - - - - - - -
Acknowledgement - - - - - - - -
Abstract - - - - - - - - - -
Table of
Contents - - - - - - - -
CHAPTER ONE
1.1 Background of the Study - - - - - -
1.2 Statement of Research Problem - - - - -
1.3 Objective of the Study - - - - - - -
1.4 Significance of the Study - - - - - -
1.5 Statement of Hypothesis - - - - - -
1.6 Scope of the Study- - - - - - - -
1.7 Limitation of the Study - - - - - -
1.8 Historical Background of the Study - - - -
1.9 Definition of Terms - - - - - - -
CHAPTER TWO
LITERATURE REVIEW
2.1 Production - - - - - - - - -
2.2 Planning - - - - - - - - -
2.3 Control - - - - - - - - -
2.4 Production Planning - - - - - - -
2.5 Production Control - - - - - - -
2.6 Planning and Control - - - - - - -
2.7 Basic Alternatives/Process Selection - - - -
2.8 Summary of Review - - - - - - -
CHAPTER THREE
RESEARCH METHODOLOGY
3.1 Research Design - - - - - - -
3.2 Research Population - - - - - - -
3.3 Sample Size and Sampling Techniques - - -
3.4 Method of Data Analysis - - - - - -
3.5 Justification of Method Used - - - - -
CHAPTER FOUR
DATA PRESENTATION AND ANALYSIS
4.1 Presentation and Analysis of Data - - - - 44
4.2 Test of Hypothesis - - - - - - - 50
CHAPTER FIVE
SUMMARY OF FINDINGS,
CONCLUSION AND RECOMMENDATION
5.1 Summary of Findings - - - - - - - 53
5.2 Conclusions - - - - - - - - 54
5.3 Recommendations - - - - - - - 55
References - - - - - - - - - 56
Appendices - - - - - - - - 57
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