 Hello friends, today we will have some discussion on loading, the next step in production planning and control, as all of us know, PPC involves the first step as routing, then scheduling and immediately after scheduling, the term comes into loading, so we are going to discuss today what is loading is and at the end of this session, all of us will understand what is the concept and the objective of loading and also we will be able to prepare a load chart for a simple conventional machine, the contents are what is the definition, objectives, what is Gantt chart, what is mean by machine loading and adjustment to machine, under loading and overloading, so these will be the points which we will be going to discuss today. What is loading? See, routing is where to decide the route, scheduling is to decide the timetable and the next step is automatically loading, what loading is involving is that it is the actual assignment of the job to the machine, routing and scheduling are the planning phases where we are doing all the paperwork and documentation and loading is the actual operational action phase which is happening on the machine shop as such, it is the study of relationship between load and capacity at work center, so that load is the work assigned to a machine or an operator and capacity is the volume of output capable of being produced in any convenient period of time. What is loading? Load in terms of our conventional meaning in PPC is that it is the actual load of the actual task, actual work, the work to be carried out for the particular activity or for the particular job, the objective of loading is that you have to have the plan of new work orders on the basis of spare capacity available, the balance between the workload in the plant and to maintain the delivery commitments, of course, the entire PPC is aimed at making the customer satisfied in terms of keeping all the commitments of delivery, quality, quantity and time also, so cost quality delivery are the major aspects of any commitment to the customer and in PPC we are mainly adhering to the quality norms and the delivery norms at the top most priority as such, so therefore loading will definitely help to maintain the delivery commitments to the customer. Loading can be done in a variety of ways and loading is also possible with the help of different charts. One of the most common chart all of you know and the question is now which is the most commonly used chart for loading? Yes, already you know is the answer is of course, the Gantt chart. It is a tool used for both loading and scheduling. For example, there are four jobs which are to be processed on three work centers. The jobs are A, B, C and D and that requires three operations like sheet metal and painting. A, C, D requires also electricals, so these are presented in a simple form called as load chart or Gantt chart. This is a typical representation of a Gantt chart where on the x-axis we are representing the dates y-axis we are talking about work centers. In the example discussed we are considering three work centers one is the painting or paint booth or painting shop other is electrical activity electrical department and the third one is sheet metal and all these colors are highlighting what are the various steps of jobs. A, B, C, D and this chart will indicate how much particular load is required for that particular operation. For example, sheet metal in Milan how many days of capacity it is total taken together to involve around nine days of capacity. Electrical may be involving around six days of capacity whereas painting may require like seven days of capacity. We will do it definitely we can get a overview of the entire loading pattern of variety of work centers with variety of jobs taken together on a single graph a graphical representation of the load versus the work centers along with time required for these in terms of number of days. So this will help us to find out which particular work center is loaded how much extent and what is the capacity available capacity being utilized and how can plan for this loading when we can plan for this loading all this information can be very well derived from this Gantt chart. Machine loading this machine load charts are also prepared to assist in production as well as routing. It shows the amount of work assigned and scheduled to each machine or group of identical machines. Loading provides a complete and correct information about the number of machines available and their operating characteristics which can be used to calculate the difference between workload and the actual capacity. Loading will give you the as a the indicator in the Gantt chart it will give you the correct picture that how much load is actually available and how much load is balanced and what is the capacity which is available capacity being booked by various orders. So that entire information will be available through machine loading. It is a simple example of a machine loading on a conventional drilling machine the machine is machine is a radial drilling machine number suppose for example 9 and on the right hand side we see that it is weak ending November 5th total hours available in that week for that particular machine are 40 hours so it may be a five days week and then we are considering around eight hours per day so total total taken together it will be around 40 hours and then we are calculating the load over here like order number first some 6993 what is the part number what is the operation number how much quantity we are going to manufacture on that what are the total hours required and what is the balance load for that particular particular job particular order similarly all the orders are getting dating it over here and then what is the total load which is available and what is the balance of the load which is available all that can be seen through this simple chart where it will give the entire tabulator information order wise machine hours wise what is the lot size and what is the total balance of the load that will give you the entire loading pattern now there can be situations where under loading and overloading may occur what is under loading that we don't have enough of jobs to process on the machine that is called as under loading and then there can be job there can be circumstances where the number of jobs are much more and the machine is not available machine capacity is already full that is called as overloading how to make adjustment in case of under loading and overloading there are typical some solutions which are possible in both the cases the first one is overloading now overloading can be handled by re-rooting of the work to machines to have allocated capacity if you are having overload then you can think of alternative machines or you can change the routing of the job itself and as a result of that those machines which are being not utilized we have to change the sequence we have to reprocess it probably reroute it and then we can use the idle machines which are otherwise not used in the normal course of time you can use it by additional making some tooling arrangements on those machines the next one is now of course this assumes the second of second alternative is operating the machines with overtime now this this assumption is that you are not operating all the machines for 24 hours you are using either one or second shift then you can use the additional shift which is available with you maybe second shift or maybe third shift as the case may be and then you can adjust the overloading with the help of additional overtime to the machines the next option is subcontracting or outsourcing some work of course it requires some again assumptions that overnight you cannot go for subcontracting you need to have a subcontracting policy you need to have some capacity outsourced which are available to you and then probably already outsourcing is possible and so suppose you are outsourcing with a capacity of 30 percent with the help of this you can go for higher percentage and the last and ultimate the end result is that instead of all those then if load is not adjusted the last option the last result available is put additional infrastructure in terms of machines and equipments you have to go for higher equipment investment itself in case of under loading naturally under loading is because of the low orders so you have to concentrate more on the sales so increase the sales therefore you can have a higher amount of loading which is possible if the sale is not today then you can forecast the sales and probably anticipates especially in case of seasonal demands or festival seasons with the help of marketing department you have to work together and anticipates some load and then anticipating the load you have to schedule that and load the machines and in spite of all these still the capacity is idle as in the case of overloading you have to purchase the machine in case of overall under loading you have to keep that machine idle in some last case last option you have to sell that machine also so these are the possible arrangements for overloading and under loading of course exact loading 100 percent loading exact as per our capacity is a dream there are situations where throughout the year some occasions will be there where you will have got some under loading circumstances and there will be some circumstances where naturally you have to face overloading in both the cases you will need not take any decision in a hurry it's a time being load adjustment we have to consider for a longer horizon of time one year two year three year and before taking any decision like selling or purchasing a machine we have to consider a long-term vision and then go for the under loading overloading adjustments okay thank you thank you one and all