Visvesvaraya Technological University,

Jnana Sangama, Belagavi – 590 018

KLS Vishwanathrao Deshpande Institute of Technology,

Haliyal – 581 329
(Accredited by NAAC with “A” Grade)

`
Department of Mechanical Engineering

Internship Report on

PRODUCTION PLANNING AND CONTROL

Submitted by
VIJET LOKESH NAIK – (2VD22ME446)
VII – Semester / III – Year

Under the guidance of

Dr. SHANKAR BADIGER
2023 – 24
 Visvesvaraya Technological University,
Jnana Sangama, Belagavi – 590 018

KLS Vishwanathrao Deshpande Institute of Technology,

Haliyal – 581 329
(Accredited by NAAC with “A” Grade)
Department of Mechanical Engineering

CERTIFICATE
Certified that the internship report entitled “PRODUCTION PLANNING AND CONTROL
SYSTEM(PPC)”carried out by Mr. VIJET LOKESH NAIK, USN(2VD22ME446),a bonafide
student of KLS VDIT, Haliyal, in partial fulfillment for the award of Bachelor of Engineering in
Mechanical Engineering, of the Visvesvaraya Technological University, Belagavi during the year
2023-2024. It is certified that all corrections / suggestions indicated for Internal Assessment have
been incorporated in the Report deposited in the Departmental Library. The internship report has
been approved as it satisfies the academic requirements in respect of internship Work prescribed for
the said Degree.

GUIDE HOD PRINCIPAL

(Dr. Shankar Badiger) (Dr. Murgayya Basavankattimath) (Dr. V. A. Kulkarni)

Name of the Examiners Signature with Date

1.

2.
 DECLAERATION

I hereby that the internship titled “PRODUCTION PLANNING &CONTROL (PPC)”, Has been
carried out under the guidance of prof. Naveen Hiremath, Assistant Professor, Department of
mechanical Engineering, KLS VDIT Haliyal, In partial fulfillment of the degree of Bachelor of
Engineering in Mechanical from Visvesvaraya Technological University, Belagavi, Karnataka
during the academic year 2023-2024.

I also declared that I have not submitted this internship to any other university for the award of any
other degree.

Place: Sirsi Vijet Naik

Date: 27-11-2023 (2VD22ME446)

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 ACKNOWLEDGEMENT
The internship opportunity I had with DIVIGI TORQ TRANSFER SYSTEM Pvt.Ltd was a
great chance for learning and professional development. Consider myself as individual as provided
with an opportunity to be part of it. I am also grateful for having a chance to get good practical and
learning experience to be in organization study

First and foremost, we would like to express our deepest thanks to Mr. Manjunath Naik, HR
Manager, DTTS Sirsi giving opportunity to do an internship with the organization.

And also am grateful to our external guide Mr. Prashant M Bhovi, Manager DTTS. Ltd Sirsi,
(Operator education and training Dept.) For the constant support and encouragement and providing
with necessary facilities. We are highly indebted to him for taking keen interest in our work,
monitoring and providing guidance throughout the internship.

And also my sincere thanks to Mr. Vinayak Deshpande, PPC Manager, DTTS Sirsi for giving
me nice opportunity to do an internship and also thanks for the support and encouragement and
providing with nice facilities and knowledge.

With profound sense of gratitude and regards I convey my sincere thanks to my internal guide
Prof. Naveen Hiremath, Department of Mechanical Engineering, for his esteemed suggestions
given to me in complete my internship.

We thank Dr. Murgayya Basavankattimath, Head of Department, mechanical engineering,

for all his suggestions and timely guidance.

We also thanks Dr.V.A. Kulkarni, Principal, KLS VISHWANATHRAO DESHPANDE

INSTITUTE OF TECHNOLOGY, Haliyal for their constant support.

Finally, I convey my sincere regards and thankfulness to all those who supported my internship
journey.

Vijet Lokesh Naik

(2VD22ME446).

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 ABSTRACT

The manufacture of gear shaping, gear shaving, debarring, broaching, tread rolling, etc. is the
foundation of the sector. I researched the many types of quality assurance testing equipment utilized
in the company, their manufacturing process, and their staff responses to manufacturing. I also
learned how to produce numerous different gears and shafts. Testing gears and shafts is crucial for
ensuring overall performance, dependability, safety, and quality. It helps manufacturers to create
dependable parts that support the efficient and effective operation of several mechanical systems. If
the gear and shafts have error in dimensions, pitch, lead errors during its manufacturing, the steps
taken to repeat the process and rectify the problem and solve it. The various types which are
manufactured for various condition like transmission gears, clutch body ring, shafts, electric vehicle
transmission etc. most of the products are supplied to TATA Motors, Mahindra Mahindra LTD.,
Chrysler, Ford Motor etc. Divgi Torq Transfer System is a joint venture between borg warner, USA
and Divgi Metalware, India establishes in the year 1995. The company has two plants one is situated
at Bhosari, Pune and other at Sirsi.

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 CONTENTS

SI NO. CHAPTERS PAGE NO.

1 INTRODUCTION 5

2 COMPANY PROFILE 6-7

2.1 Founders

3 DIVGI-TTS PRODUCTION SYSTEM 8

4 CUSTOMERS 9

5 VISSION,MISSION AND QUALITY STATEMENT 10

6 PRODUCTION PLANNING AND CONTROL 11

7 STEPS IN PPC 12-13

7.1 Production planning
7.2 Production control

8 DECISION MAKING 14-15

8.1 Importance of ppc
8.2 Objectives of ppc
8.3 Advantages of ppc
8.4 Limitations of ppc

9 CYCLE TIME 16
9.1 Cycle time calculation

10 CYCLE TIME PARAMETERS 17

10.1 Internal factor
10.2 External factor

11 CONCLUSION 18

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CHAPTER-1
INTRODUCTION

Manufacturing is a critical component of the economy, providing employment and generating goods
that are used by individuals and other businesses. Manufacturing industries produce everything from
consumer goods to industrial equipment and are essential to the growth and development of a country.

As a manufacturing intern, I had the opportunity to gain hands-on experience in the manufacturing
industry and learn about the different aspects of the production process.
Throughout my internship, I was able to observe and participate in various tasks, such as production
planning, quality control, and operations management.

This report aims to provide an overview of my internship experience in the manufacturing industry,
including the tasks I undertook, the skills I acquired, and the challenges faced There port will also
discuss the importance of manufacturing industries in the economy and the various factors that affect
their growth and success.

Overall, my internship experience in the manufacturing industry was valuable and provided me with a
deeper understanding of the complexities involved in the production process Through this report, I
hope to share my insights and experiences with others who are interested in pursuing a career in
manufacturing

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CHAPTER-2
COMPANY PROFILE

Divgi Metalware’s Limited was established in 1964 as a small-scale manufacturing enterprise

specializing in the manufacturing of gears and screwed machined parts, Serial entrepreneurship
combined with a robust foundation in gear technology and manufacturing enabled the founding
members, Ramarao and Bhaskar Divgi to carve a niche for themselves in a daunting marketplace that
was strife with uncertainty and complexities of that era.

Creativity and innovation enabled the company to develop its capabilities and competencies which
won the attention of a new generation of customers such as John Deere, JCB, Caterpillar and Bog
Warner. The relationship with Borg Warner grew into a market development arrangement that
quickly metamorphosed into a joint venture in 1995. The JV was dissolved in 2016 and Divgi Torq
Transfer Systems was formed as an independent company. Divgi TTS has evolved to become one of
India's leading Tier 1 companies in the design, development and manufacturing of advanced
drivetrain components and systems.

The company has a diverse portfolio of products which includes mechanical as well as electrical 4x4
transfer cases, interactive torque couplers, dual & triple cone steel synchronizers, dual clutch
automatic transmissions, 5&6 speed manual Parts and single speed electric vehicle (EV)
transmission. Divgi TTS has, over the years built an enviable customer base which includes Toyota,
Mahindra & Mahindra, Tata Motors. The company has stamped its global footprint being a trusted
supplier to customers in Russia and USA, Thailand, Korea.

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 2.1 FOUNDER

Fig.2.1 Photos of Founders

Founders: Ramarao RN,Divgi , Bhaskar BN Divgi

Year of Institution:
• 1964 - Divgi Metalware's pvt . Ltd. — DMPL
• 1995 - Divgi Warner pvt. Ltd. (JV with BorgWarner, USA)
• 2016 - Divgi Torq Transfer System Pvt. Ltd
• 2022 - Divgi torq transfer system.Ltd
Plant Locations:
• Bhosari, Pune
• Shivare, Pune Dist. Maharashtra
• Sirsi, Karnataka
• Shirval, Satara Dist. Maharashtra
Current Workforce: 500+
Products: Range:
• Specialized and highly engineered solutions for 4WD/AWD vehicles
• Manual Transmissions, Dual Clutch Transmissions and Electric Vehicle
• Synchronizers for transmissions
• Components for the above products
• Components for the above products
Capabilities: Products design & development, application engineering, manufacturing, supply
and after-sales support
Segment Presence: Utility Vehicles, Electric Vehicles, Passenger Vehicles, Agriculture,
Commercial, Industrial and Construction Equipment Customer Base Global - India, UK,
Russia, Korea, China, Thailand, USA.

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CHAPTER-3
DIVGI-TTS PRODUCTION SYSTEM:

To achieve the flawless quality and customer satisfaction, organization follow robust manufacturing
systems, which is recognized as Divgi-TTS Production system. It consists of 7 foundational elements
and 23 tactical strategies. These elements have helped to achieve Zero safety incidences, Meeting the
on-time customer's SOP launch timeline, reduction in quality PPM, and 100% on-time Deliveries to
customers and inculcates a system of continual improvement

Fig.3.1 divgi-TTS Production System

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CHAPTER-4
CUSTOMERS
Components and products have a presence in vehicle applications in some of the world’s most
trusted band names.

Fig.4.1 Customers Brand Logos

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CHAPTER-5
VISION MISSION AND QUALITY STATEMENT

 VISION STATEMENT
To be recognized as a words class Indian brand in automotive driven train components and system.

 MISSION STATEMENT
To help our customer and our people continuously involved and excel at world class levels.

 QUALITY STATEMENT
Quality driven management and employee dedication are keys to success and customer satisfaction.
Divgi-TTS is committed to building products that are sound and dependable. We will improve our
business continuously in quality, cost, and reliability. We will consistently provide products and
services, which meet or exceed customer expectations, and satisfy customers by anticipating their
requirements. Divgi-TTS seeks to achieve and maintain a reputation of excellence throughout the
communities it serves.

 SUPPLIER ENGAGMENT
At Divgi-TTS, the establishment and maintenance of effective relationships remains a cornerstone of
our business. Divgi-TTS works closely with its suppliers to reduce waste, improve performance, and
advance technology in the most competitive and creative ways. If you are a current Divgi-TTS
supplier, it appreciates your ongoing and unwavering commitment to these shared ideals. If you are
interested in becoming a supplier to Divgi-TTS, this portal is designed to get you on the right track

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CHAPTER-6
PRODUCTION PLANNING AND CONTROL,
The production planning department is responsible for ensuring the manufacturing operations run
smoothly and efficiently. They do this by planning and controlling the flow of material, equipment
and labor throughout the production process.

 PRODUCTION PLANNING
Production planning is the process of forecasting ahead every step in the long process of production,
taking them at the wright time in the right degree and completing the operations at the maximum
efficiency.

 PRODUCTION CONTROL
Production control is the process of keeping watchful eye on the production flow by utilizing
different types of control techniques to achieve optimum performance out of the production system
as to achieve overall production planning targets.

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CHAPTER-7
STEPS IN PPC
7.1 PRODUCTION PLANNING

 PLANNING
In production planning, planning is the process of determining what products will be produced, in
what quantities, and when. It is a critical step in the production planning process, as it ensures that
the business has the necessary resources to meet customer demand and achieve its production goals.

 ROUTING
In production planning, routing is the process of determining the sequence of operations and the
machines or work centers required to produce a product. It is a critical step in the production
planning process, as it ensures that the product is produced efficiently and to the desired quality
standards.

 SCHEDULING
In production planning, scheduling is the process of determining when each operation in the
production process will be performed. It is a complex process that must take into account a variety of
factors, including the availability of resources, the desired production lead time, and the need to meet
customer deadlines.

 LOADING
In production planning, loading is the process of assigning specific jobs to machines, men, or work
centers based on relative priorities and capacity utilization. Loading is typically done after the
production schedule has been developed. The goal of loading is to ensure that all machines and work
centers are efficiently utilized and that all jobs are completed on time.

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7.2 PRODUCTION CONTROL

 DISPATCHING
In production control, dispatching is the process of releasing work orders to the production floor. It is
the final step in the production planning and control process, and it ensures that the right work is
done at the right time and in the right sequence. Dispatching is an important part of production
control because it helps to ensure that the production process runs smoothly and that products are
delivered to customers on time.

 FOLLOW UP
In production planning control, follow-up is the process of monitoring and tracking the progress of
production orders to ensure that they are completed on time and to budget. It is an important part of
the production planning and control process, as it helps to identify and address any potential
problems early on. Follow-up can be done manually but it is often more efficient to use a production
planning and control software program.

 INSPECTION
In production planning control, inspection is the process of verifying that products and materials
meet quality standards. It is an important part of the production planning and control process, as it
helps to ensure that only high-quality products are delivered to customers.

 CORRECTION
In process planning control, correction is the process of identifying and addressing deviations from
the production plan. It is an important part of the production planning and control process, as it helps
to ensure that the production process runs smoothly and efficiently. Correction can be done at any
stage of the production process, from incoming inspection to final inspection.

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CHAPTER-8

DECISION MAKING IN PCC

What to produce  product planning & development including design

How to produce  material planning, process planning, tool equipment planning

Where to produce  Facilities planning, capacity planning, subcontracting

When to produce  production scheduling, machine loading

Who will produce  man power planning

How much to produce  Qty Planning, economic batch size

8.1 IMPORTANCE OF PPC

 For increasing production

 For quality output

 For cost control and minimize wastage

 On time production output

 For systematic, smooth running of activities

8.2 OBJECTIVES OF PPC

 Production of quality products

 Maximum utilization of resource

 Economy at production time

 Optimum inventory level maintenance

 To ensure smooth flow of operation

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8.3 ADVANTAGES OF PPC

 Enhanced Efficiency and Productivity

 Improved Quality Control

 Reduced Costs

 Timely Delivery and Customer Satisfaction

 Improved Inventory Management

 Enhanced Decision-Making

 Adaptability to Change

 Streamlined communication and collaboration

8.4 LIMITATIONS OF PPC

 Based on assumptions.

 Employees may resist changes.

 Time-consuming process.

 Difficult due to change in environmental factors.

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CHAPTER-9
CYCLE TIME
Cycle time is a key metric used in manufacturing and production to measure the overall efficiency of
the production process. It represents the average amount of time it takes to complete one unit of a
product from start to finish. Cycle time is often confused with lead time, but they are distinct
concepts.

Cycle time is an important metric for several reasons:

1. It measures efficiency

2. It identifies bottlenecks

3. It helps with planning and scheduling

4. It contributes to continuous improvement

9.1 CYCLE TIME CALCULATION

The formula for calculating cycle time is:
Cycle Time = Total Production Time / Number of Units Produced
Where:
Total Production Time: The total time it takes to produce a batch of products, including all
processing, assembly, inspection, and setup time.
Number of Units Produced: The total number of units produced in the batch.
For example, if it takes 600 minute to produce 50 units of a product, the cycle time would be
calculated as:
Cycle Time = 600 minute / 50 units = 12 minute per unit

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CHAPTER-10

CYCLE TIME PARAMETERS

Cycle time parameters are the various factors that influence the amount of time it takes to complete a
specific task or process. These parameters can be broadly categorized into two groups:

10.1 INTERNAL FACTOR

Task complexity: The complexity of the task itself can significantly impact cycle time. More
complex tasks with multiple steps and dependencies will generally take longer to complete than
simpler tasks.
Resource availability: The availability of resources, such as equipment, tools, and personnel, can also
affect cycle time. If resources are limited or unavailable, it can lead to bottlenecks and delays.
Process efficiency: The efficiency of the process itself can also influence cycle time. Inefficient
processes with unnecessary steps or rework can add to the overall time it takes to complete the task.

10.2 EXTERNAL FACTOR

Customer demand: Customer demand can influence cycle time by creating variability in the
workload. If demand is high, it can lead to longer cycle times as there is more work to be done.
Conversely, if demand is low, cycle times may be shorter.
Supplier performance: The performance of suppliers can also impact cycle time. If suppliers deliver
materials or components late or with defects, it can disrupt the production process and increase cycle
time.
External disruptions: External disruptions, such as natural disasters or power outages, can also cause
delays and increase cycle time.
By understanding and managing these cycle time parameters, organizations can improve the
efficiency and effectiveness of their operations. This can lead to reduced costs, improved customer
satisfaction, and increased competitive advantage.

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CHAPTER-11
CONCLUSION
The internship at Divgi Torq Transfer system was an enriching experience that helped me again
practical knowledge about the functioning of a well-established industry. During the internship, I got
the opportunity to interact with various professionals and learn about the different facets of working
in the industry. The hands-on experience of working in different departments and studying the
company’s manufacturing process and products helped me understand the industry’s functioning in
depth. I also learned about the importance of safety measures, energy consumption, and the role of
different machinery in the production process. Overall, the internship provided me with valuable
insights and practical knowledge that will help me in my future career as an industry professional.
The exposure to the industry’s working has helped me to develop my skills and increase my
understanding of the industry’s operation, quality control, and production. In conclusion, the
internship was a great experience that has enhanced my learning and personal development.

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