International Journal of Advanced Engineering Research and Technology (IJAERT), ISSN: 23488190

th
st
ICRTIET-2014 Conference Proceeding, 30 -31 August 2014

A TOOL FOR PRODUCTION PLANNING AND CONTROL SYSTEM

Shweta Hegde1, T Satish Kumar2, Manjunatha M B3
1
2

Department of CSE, RNS Institute of Technology, Bangalore, India

Department of CSE, RNS Institute of Technology, Bangalore, India
3
General Manager, WinfoGlobal Technologies, Bangalore, India

ABSTRACT
The production planning and control system is
concerned with planning and controlling of all aspects of
manufacturing,
including
managing
materials,
scheduling
machines/people,
and
coordinating
suppliers/customers. The major part of production
planning for any manufacturing company is the business
operations. Whether producing goods or services for
their consumers, companies invest vast amount of capital
and resources in an effective and efficient manner.
Properly managing these production processes is an
important factor of success.
The proposed system is used by those industries,
which wants to efficiently manage the whole production
cycle
by
market-oriented
event-oriented
and
computerizing functional model of their production
plants. The system encompasses the activities of
procurement, allocation and utilization of resources. The
main objective of the system is to ensures that materials,
equipment and human resources are available to
complete the work efficiently by organizing the supply
and movement of materials and labour, machines
utilization and related activities, in order to bring about
the desired manufacturing results in terms of quality,
quantity and time in the most efficient and economical
way. The system is developed using advanced
technologies viz. Spring, Hibernate to achieve
economical and efficient system.
Keywords - ERP, Hibernate, Manufacturing,
Spring MVC

1. INTRODUCTION
Service based applications have gained more
attention by industries over the years. There are many
requirements in information system because of changing
technologies in Production Planning and Control (PPC)

System in recent years. The evolution of Web

Technologies and XML has brought PPC functionalities
over the web. Service based applications will replace
today's Enterprise Resource Planning applications.
Service identification for given production planning and
control is designed in this project. Optimization of the
internal process of an Enterprise is the main concern in
traditional ERP. The ERP is not much concerned with
interaction with external parties. Cooperation with
external parties as well as Optimization of the internal
process are considered in this project. The project is
carried out at WinfoGlobal technologies, Bangalore from
August 2013 to May 2014.

2. RELATED WORK
M. Eisele et al.[1] and K. Klose et al.[2]
analyzed that service based applications have received
an increasing attention over the years in both academia
and in industry. Business activities and cooperation with
customers, Vendors and competitors are very important
in present ERP system. Business innovation
collaboration will require dynamic end-to-end and
runtime optimization of business process across value
chains according to Yuan-Chwen You et al. [5]. To
establish such an End to End ERP system Business
Process Management (BPM), Service oriented
Architecture (SOA) and Semantic Web technologies are
used. Material Requirements Resource planning,
Manufacturing Resource Planning is motivation for
Enterprise Resource Planning. SOA offer new way to
accomplish Enterprise Resource Planning /End to end
Enterprise Resource Planning (EERP). BPM on SOA
combines software capabilities and business expertise to
advance in optimization of the end to end business
process. Therefore BPM and SOA are combined as the
central technology for EERP. N. Slack et al. [11] stated
that PPC ensures that the production occurs efficiently
and effectively to meet customers requirements. Any

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International Journal of Advanced Engineering Research and Technology (IJAERT), ISSN: 23488190
th
st
ICRTIET-2014 Conference Proceeding, 30 -31 August 2014

manufacturing system must be time-driven, time

oriented and easily adaptable according to Alina Girbea
et al. [14].
The ultimate objective of PPC is to organize the
supply and movement of materials and labour, machines
utilization and related activities, in order to bring about
the desired manufacturing results in terms of quality,
quantity, time. Development environment used in this is
Eclipse and developed using J2EE which is Open and
standard based platform for developing deploying and
managing n-tier, Web enabled, server-centric and
component-based enterprise application. Hibernate with
Spring MVC architecture is used to get economical and
efficient product for small scale industries. Christian
Bauer et al. [12] describe Hibernate as a full
object/relational mapping tool. Spring MVC framework
provides model-view-controller architecture that can be
used to develop flexible and loosely coupled web
applications.
L. Mnch et al. [6] proposed three models for
SOA viz. Process model, service model and Technique
model. There are many issues in Service and Technique
model layers. It examines how service models can be
obtained for the Production Planning and Control (PPC)
domain and deals with Design of Service model and
design of Technique model. Three prototypes are
designed and implemented to study the technical options
to provide PPC functionality for the ERP system mySAP
ERP where Web services are used to stretch out the
functionality of existing ERP systems and to join the
ERP systems with other applications and possibilities for
providing PPC functionality using web services where
ERP systems are constructed from scratch based on web
services. Prototype I proposes a service to plan the
release dates of production orders and services to read
and write the necessary data from/into a mySAP ERP
instance. Prototype II extends the functionality of the
prototype I by providing Material Requirement Planning
(MRP) logic. Prototype III encloses optimization-based
approaches for a short-term demand forecast in the
supply chain of a large German semiconductor company
using a self-contained web service based application.
Baoan Li et al. [7] explains support by EERP
(End-to-End Resource Planning) for the current business
challenge. Main service requirement for EERP is
analysed. They are Service issuance issues the services
in the service register library, and then offer the detailed
introduction about service function and QoS (Quality of

Service), Service finding is used to locate the appropriate

services according to the business goal. Service selection
is used to select the appropriate services according to the
business goal. Service consulting consult with the
service provider and the service consumer, and then to
make terms at QoS and SLA (Service-Level
Agreement), Service combination assembles and binds
the services Service harmonizing used to resolve the
harmonizing problem among the protocol, data, process
and application, and then to procure the optimization
result. Process simulation arranges the correlative
properties and runs at the BPM layer analogously, so
that to find the potential problems before deploying the
business process. Process implementing can connect and
employ the services, and process the exceptions
dynamically through the service finding, service
selection and service consulting. Baoan Li et al. [7]
proved that process optimization can find the most
effective business process through analysing, monitoring
and simulating procedures on BPM layer. PROMME is
one of the methodologies to enable manufacturing and
control management in a distributed manufacturing
environment according to Alberto J. lvares et al. [13].
This methodology is applied for WebMachining virtual
company and the process is explained in the the project.
EERP is different from traditional ERP. ERP
systems were focused on optimization of the enterpriseinternal process, and not equipped with interaction
possibilities with external parties as described by Baoan
Li et al.[8]. Business Process Management (BPM) on
SOA is discipline that combines software capabilities
and business expertise to increase optimization of the
end-to-end business process according to Baoan Li et al
[8]. Therefore, BPM and SOA technologies are joined as
the core technology for EERP. BPM is basically a topdown approach but SOA is usually bottom-up. They are
complementary to each other even though there exists
some differences between them. BPM can consume
business services that are defined and managed using
SOA. SOA ease the path for BPM proliferation, Thus
processes modelled by BPM tools can be rapidly
implemented by SOA. The BPM-SOA combination
allows reusability of services. This has the capability
which leads to increased agility, more transparency,
more economical and a better adjustment between
business and IT. Baoan Li et al. [9] explained that SOA
development processes are divided into three phases:
First one focuses on the integration in enterprise and
resolves the One to One relations, Second one
concentrates on the value chains between the credible

Divya Jyoti College of Engineering & Technology, Modinagar, Ghaziabad (U.P.), India

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International Journal of Advanced Engineering Research and Technology (IJAERT), ISSN: 23488190
th
st
ICRTIET-2014 Conference Proceeding, 30 -31 August 2014

associate enterprises and resolves the One to Many

relations, Third one deals with finding new relations and
new services. It resolves the Many to Many relations.
Services join functionality with implementation
according to John Hutchinson et al [10]. It describes
future of SOA that services should be coarse grains,
Discoverable, Loosely coupled, etc.

3. MATERIALS AND METHODS

The system provides computerized, market oriented,
event oriented functional model of production process to
provide high degree of services to the customers. The
main functionalities of the system are production process
flow control, employee management, report generation
for materials, product, stock, issues etc., and
maintenance of employee profile, assigned work,
product management and product quality control. It
facilitates check points in each and every stage of the
production cycle so that assures efficient planning and
quality production. Event driven message triggering
keeps track of the production line always.

Schedule module. If components are sufficient for the

process then next action is taken. If components are not
sufficient then Purchase order for the components are
raised by Purchase department and same is
communicated to Vendor by the purchase department.
Schedule module handles scheduling of Machines, Shift,
and Labours. It collects human resource information
from Employee Module and sends machine information
to JobCart. It also sends produced goods to Production
control module where Quality is checked and rejected
items are sent back for reworking to Schedule module
and same cycle repeats. Employee module contains
employees personal and professional information along
with user name and password. JobCart contains the
machine and corresponding job related information like
machine downtime, components in particular machine
etc.

Preparation of time and action report for each

order from order receiving to shipment is provided in the
system. The job schedule contains list of tasks to be
processed. Each tasks planner mentions when to start a
task and what is dead line for that task. The
manufacturing activity of a plant is said to be in
control when the actual performance is within the
objectives of the planned performance. Quality control
and Rework system ensures the same. The system also
includes inventory management i.e. Sales, Purchase,
store and vendors. Reports of sales, purchase order, Bill
of Materials, vendors, Rejected materials are provided in
the system for analysis purpose. Event driven message
triggering is also provided to ensure the uninterrupted
production process.
3.1 System Architecture
The system architecture contains five main modules
viz. Inventory, Schedule, Production control, Employee
and JobCart as shown in Fig. 1 interact among them and
take care of resource flow in manufacturing process.
Inventory module handles the functionalities of Store,
Vendor and Purchase departments. Whenever a
production order is given, Component availability is
checked by Schedule module. Inventory module sends
information of requested component from Store to

Fig. 1 System Architecture

3.2 Implementation

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International Journal of Advanced Engineering Research and Technology (IJAERT), ISSN: 23488190
th
st
ICRTIET-2014 Conference Proceeding, 30 -31 August 2014

Proposed system is developed in Eclipse using

Spring MVC architecture with Hibernate technology on
J2EE platform. Tomcat server is used to provide web
based access. Spring MVC separates roles played by the
various components. Business data are bound in a model
and movement of data takes place from presentation
layer to data store through models. Hibernate takes the
role between Data store and the application. Application
interact with hibernate objects instead interacting with
database tables to update, delete and select and other
queries. JavaScript, HTML, CSS are the components of
Client side and Spring, Hibernate are in server side.

reworked are retrieved from the Item to rework page.

Employee details can be added and edited through
Employee page and Machine and job related information
is fetched through the Job cart page.

When the client requests to server then

Dispatcher servlet in the server receives the request and
resolve the request to controller. Respective controller
knows how to handle the request and takes action
accordingly. If the request needs database then the
controller invokes data access object to fetch data or
store data from/to the database. Data set (if any) are sent
back to the controller and entire set of requested data are
encapsulated in a model and sent as response to the
requested page. If database interaction is not required
then business data are encapsulated in a model and sent
as response to the request.
.
The system used to implement this tool had Intel
i-3, 3.40 GHz processor, 8 GB Ram with windows 8.1 as
operating system.

4. RESULTS AND DISCUSSION

Fig. 2 shows the screen shot of Quality Control
page of the implemented system. Pages corresponding to
sub module of the each module as show in the system
architecture are provided in the tool. Store, Purchase,
Vendor sub modules pages allow user to enter
component details to respective department and user can
retrieve details from the store as well. The sub module
pages of schedule module Machine, Shift and Batch
allow admin to schedule the machine time to particular
shift and for particular batch of employees. Details of
which are stored and retrieved using the respective
pages.
Quality Control page shows the quality related
details and authorized person can add quality
information to database for every items produced.
Details of rejected items are stored through the Rejected
Items page and more specific details of item to be

Fig. 2 Quality Control

5. CONCLUSION
ENHANCEMENT

AND

FUTURE

The implemented system provides complete visibility

into all the important processes and ensures a smooth
transition and quicker completion of processes. This also
ensures that all the inter-departmental activities are
properly tracked and none of them is missed out.
Since a Database system is implemented on the
backend to store all the information required by the ERP
system, it enables centralized storage/back-up of all
enterprise data. The system reduces labour by
eliminating waste of time and improves process flow and
utilizes full potential of human resources. The system
ensures on time deliveries products and handles
following up with the changes. Changes may happen
every day so delivery time may move up or work
parameters have to be adapted. Organization may need
to adjust the plan and follow up with various
departments. The proposed system is helpful in tracking
the changes, inventory, employees and equipment.

Divya Jyoti College of Engineering & Technology, Modinagar, Ghaziabad (U.P.), India

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International Journal of Advanced Engineering Research and Technology (IJAERT), ISSN: 23488190
th
st
ICRTIET-2014 Conference Proceeding, 30 -31 August 2014

ACKNOWLEDGMENT

[9] Baoan Li, Weizhen Zhou, Research on End-to-End

Resource Planning and
Dynamic Semantic Integration on Web Services,
Beijing Education Committee Science and Technology
Development Plan Item (KM200810772008)

I express profound gratitude to Mr. Mohan K S,

Project Manager, Winfoglobal Technologies Pvt. Ltd,
Bangalore for providing me opportunity and
guidance.

[10] John Hutchinson, Gerald kotonya, james

Walkerdine, Peter Sawyer, Glen Dobson and Victor
Onditi, The challenge of Evolving Existing systems to
Service-Oriented Architectures 2007 IEEE

The implemented system may be developed to

handle more than one manufacturing plant of a company.
Fully automated system may be implemented to achieve
least manual intervention.

REFERENCES
[1] M. Eisele, R. Kolb, E. Kraus, and C. von Ehrenstein,
"SAP NetWeaver:
slicing the fridge, " Informatik
Spektrum, 30(6) (2007), pp. 407-412.
[2] K. Klose and R. Knackstedt, "Serviceidentifikation
fr die Produktionsplanung eines mittelstndischen
Auftragsfertigers,"
HMD

Praxis
der
Wirtschaftsinformatik, 253, (2007), pp. 47-56.
[3] W. Hopp and M. Spearman, Factory Physics, second
edition, McGraw-Hill, (2001).
[4]
AMR,
"SOA
will
kill
ERP,"
http://blogs.zdnet.com/serviceoriented/? p=689, (2009).
[5] Yuan-Chwen You, James Guo, EERP: End-to-End
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[11] N. Slack, S. Chambers and R. Johnston, Operations

Management. 4th Edition, Finantial Times/Prentice-Hall,
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[12] Christian Bauer, Gavin King JAVA
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[13] Alberto J. lvares, Jos L.N. de Souza Jr., Evandro
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[14] Alina Girbea, Constantin Suciu, Member, IEEE,
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the Optimization of Industrial Applications, IEEE
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february 2014 185

[6] L. Mnch, J. Zimmermann, Providing Production

Planning and Control Functionality by Web Services:
State of the Art and Experiences with Prototypes, 5th
Annual IEEE Conference on Automation Science and
Engineering Bangalore, India, August 22-25, 2009
[7] Baoan Li, Jingzhi Liu, Research on Dynamic
Semantic Integration of EERP Based on SOA,
Proceedings of 2009 4th International Conference on
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[8] Baoan Li, Weizhen Zhou, Research and Design of
EERP:End-to-End Resource Planning Based on SOA
and BPM, Beijing Education Committee Science and
Technology Development Plan Item (KM200810772008)

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