MINIMIZING DEFECTIVE PRODUCT THROUGH EFFECTIVE PRODUCTION PLANNING AND CONTROL IN DEFENCE INDUSTRIES CORPORATION OF NIGERIA

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TABLE OF CONTENT

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

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:

An analysis of the article to determine what to make and what to buy.
To determine the quality and type of material.
Determining the manufacturing operations and their sequence.
A determination of lot sizes
Determination of scrap factors
An analysis of cost of the article
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:

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.

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