ABSTRACT
This research work, accessing the impact of
production planning and control on productivity in the manufacturing industry.
This study is focused on Nigeria Bottling Company (Coca-Cola), Kaduna. The
study covers five chapters, Chapter one introduces the subject matter and
spells out the significance of the study. Chapter two make criteria review of
the current literature on the subject matter. The third chapter presents the
methods of data collections, chapter four shows the presentations and the
analysis of the data collected from the respondents. The fifth chapter shows
the summary, recommendation and conclusion. The population for this study
covers three hundred staff of Cocacola, the researcher randomly selects thirty
staff as his sample size. The hypothesis formulated of his study includes: H0:
Effective production planning and control do not enhance organizational
productivity. H1: Effective production planning and control enhance
organizational productivity. Data collected were presented and analyzed in a
tabular form using percentage. It was further tested with the use of chi-square
and hypothesis was confirmed.
TABLE OF CONTENTS
CHAPTER ONE
INTRODUCTION
1.1 Background of the Study - - - - - - 1
1.2 Statement of the Problem - - - - - - 3
1.3 Objectives of the Study - - - - - - 4
1.4 Statement of Hypothesis - - - - - - 5
1.5 Significance of the Study - - - - - - 5
1.6 Scope of the Study - - - - - - - 5
1.7 Limitations of the Study - - - - - - 6
1.8 Historical Background of the Case Study - - - 7
1.9 Definition of Terms - - - - - - - 8
CHAPTER TWO
LITERATURE REVIEW
2.1 The Meaning of Production - - - - - - 10
2.2 Production Planning - - - - - - - 12
2.3 Production Control - - - - - - - 18
2.4 Planning and Control - - - - - - - 20
2.5 Relationship between Production Planning and
Control - 25
2.6 Production Design and Process Planning - - - 25
2.8 Basic Alternative/Process Selection - - - - 27
CHAPTER THREE
RESEARCH METHODOLOGY
3.1 Research Design - - - - - - - 30
3.2 Research Population - - - - - - - 30
3.3 Sample Size and Sampling Techniques - - - - 31
3.4 Methods of Gathering Data - - - - - - 31
3.5 Justification of Method Used - - - - - 33
3.6 Method of Data Analysis - - - - - - 34
3.7 Justification of Instrument Used - - - - - 34
CHAPTER FOUR
DATA PRESENTATION AND ANALYSIS
4.1 Data Presentation - - - - - - - 35
4.2 Data Analysis - - - - - - - - 43
4.3 Test of Hypothesis - - - - - - - 46
CHAPTER FIVE
SUMMARY, CONCLUSION
AND RECOMMENDATIONS
5.1 Summary - - - - - - - - - 49
5.2 Conclusion - - - - - - - - - 49
5.3 Recommendations - - - - - - - 50
References - - - - - - - - 52
Appendix - - - - - - - - - 54
CHAPTER ONE
1.1 BACKGROUND
OF THE STUDY
Production
Planning and control are terms that though commonly used have witness a lot of
changes both in meaning and scope in the past four years, for example, based on
the extended view of production to include the tradition of all of production
services both as discipline of study and as a profession can now be practiced
in all kind of organization. As in other field of management, planning and
control forms the primary function of the production management. It is for this
reason that this research has decided to take a critical look at production,
planning and control as practiced in beverage industrial sector of the Nigeria
economy. This is informed by the variety of major product and beverage produce
in industry as exemplified by Nigerian Bottling Company (NBC) Kaduna.
Buffa
(2002) defined production as the process by which goods and services are
created. Production cab be regarded as the central focus of any manufacturing
concern. It is that stage where the real action takes place i.e. the
transformation of raw materials (input) into finished products (output). The
planning and control operation are necessary because in every manufacturing
unit there are people, machine and materials. There is the need to plan all
expensive resources required for production in order to make effective use of
them and maximize profit making for the organization.
Modern
production is complex hence both technologically related operation and
administrative activities must therefore be planned carefully to make account
of all the possible restructure, constraints and advantages. In planning to
meet order at less cost in the object of production planning.
According
to Mayer (2002), there is a logic behind the operation of the production
process, it sterns from the types of technology as well as in type of
production in the particular manufacturing process.
Wild
(2002) defined production as a managerial function that tends to design, plan
what to produce, when to produce, where to produce and for whom to produce, the
quantity, the quality to produce and for whom to produce. These function
attempts to define the key decision model involved in production i.e. the long
term and the short term planning and as well as identify the procedure and
their control in a cost effective way.
Apple
(2002) defined it as the activity of transforming raw material or component
into finished product” whatever the definition it is clear that production
essentially entails the production of goods and services.
Production
planning involve not only the types of operation to the used but the order of
these operations as well as a time or duration the operation should take how
the plan should be laid out.
1.2
STATEMENT
OF THE PROBLEM
Most
organization production certainties are slow and time given to complete a given
task always exceeds the expected given time. This study intends to investigate
and know the reasons behind productivity among the employees.
And
also a times, the use of quantitative techniques in assigning jobs in an
organization, it is properly maintained, they get short of material due to lack
of good control of stock. The scope and concept of production management is not
fully known in some managers. The problem of production planning and control
will be discussed in this work and solution.
Lastly,
the study intends to know the problems associated with activities of planning
in relation to Cocacola Production and Solution suggested.
1.3
OBJECTIVES
OF THE STUDY
The
following are the objectives of this study:
i)
To assess the impact of production
planning and control on manufacturing industry.
ii)
To determine how effective planning and
control enhance organizational productivity.
iii)
To identify the strategy for enhancing
the organizational productivity.
iv)
To assess adequacy in controlling
materials.
1.4
STATEMENT
OF HYPOTHESIS
H0:
Effective production planning and control do not enhance organizational
productivity.
H1:
Effective production planning and control enhance organizational productivity.
1.5
SIGNIFICANCE
OF THE STUDY
The
significance of this study cannot be overemphasized, because it helps manager
and organization to minimize the production time and costs, by telling a
production facility when to make with which staffs on which equipment or method
to apply at any given situation or circumstances. It will also help the
organization to maximize the efficiency of the operation and reduce costs
thereby maximizing profit through effective use of plant and machines and by
taking corrective measures. The organization will see it own lapses and improve
on them so as to meet it own objective; other organization in the organization
same time take correction on their production system.
1.6
SCOPE
OF THE STUDY
Production
Planning and Control being a complex and dynamic concept has a wide area of
coverage so it is clear that research of this nature cannot hold without
problem. As such this work is limited to the area that are relevant to the
problem under investigation that is effective production planning and control
on manufacturing industry taken Nigerian Bottling Company as a Case Study.
The
major areas covered are the bottling line where the actual production
scheduling and programming activities mostly take place. It covers other
department in relation to production because they are all interrelated.
1.7
LIMITATIONS
OF THE STUDY
In
the course of writing this work some limitations were encountered. For
instance, the high cost of transportation limited the movement of the
researcher. Also time constraint or limitation is another factor since the
semester is a short one.
Another
problem encountered is the respondents attitude while administering the
questionnaire some of the employees showed non chalant attitude towards this
work. Despite these problems faced, the researchers was lucky to gather enough
materials necessary for the successful completion of the project.
1.8
HISTORICAL
BACKGROUND OF THE CASE STUDY
Coca
– Cola is the world – leading manufacturer of soft drinks sold in more than 145
countries. A total of 250 million bottles are consumed daily in all parts of
the globe from Canada in
North to Argentina and New Zealand in the South, from Alaska
to China, from Mexico down to Nigeria. Coca – Cola first came to Nigeria in 1953 when Nigerian Bottling Company
set up its first plant in Lagos.
AJ Leventis brought Coca – Cola to Nigeria and is the owner of
Nigerian Bottling Company (NBC).
The
first plant was built in Apapa, Lagos.
The Coca – cola company in Kaduna
was established in the year 1976 when bottling commenced. It was to be the
beginning of an exciting story of growth and development particularly during
the last 10 years of the 20th century.
Nigerian
Bottling Company is today Nigeria’s
No. 1 bottler of s oft drinks, selling more than 6 million bottles a day. This
figure made which is still gaining with the continuing expansion of the
existing 12 plants and the opening of new plants in various parts of the
federation.
The
success of the Coca – cola has brought with it the development of a number of
many industries, all contributing to the growth of the Nigerian economy, the
Delta Glass Company, Ugheli which supplies millions of bottles requires to keep
a large bottling company in operation in operation and the crown product
factory in Ijebu – Ode and Kano which manufacture the metal crown used to seal
the bottle. The Benin Plastic Company makes plastic crates for carrying the
bottles. In addition, the trucks which are familiar in many parts of the
country delivering soft drinks to more than sixty thousand dealers are
assembled in Nigeria.
Nigerian Bottling Company employs over 6,00 Nigerians in all fields of
operation.
1.9
DEFINITION
OF TERMS
i)
Production Schedule: This
master production schedule comes next in sequence of events to produce products
and services. It is proceeded by demand forecast and production plan.
ii)
Process Layout: This
is characterized by situation in which similar machines and services are
located together.
iii)
Line Layout:
This is a production in which the products moves down a line, pass successive
work situation where one operation is done after another.
iv)
Intermittent Production:
This is where physical facilities must be flexible enough to handle a wide
variety and size. The basis nature of activities impose change of the design.
v)
Inventory:
This is keeping track of stock of materials needed for work at any point in
time for the smooth operation of the business.
vi)
Materials:
These are items used directly as part of the product being produced.
vii)
Production:
Process of producing and manufactured goods.
viii)
Planning:
Is an act of selecting from relevant set of options.
ix)
Control:
This is a process of unifying the effort of selection and department in an
organization of each section.
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