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Production system

The document outlines the characteristics and types of production systems, emphasizing the organized nature of production aimed at transforming inputs into outputs while incorporating feedback for performance improvement. It details intermittent production systems, including job and batch production, as well as continuous production systems such as mass production, process production, and assembly line production, highlighting their advantages and limitations. Each production type is characterized by its operational flow, machinery usage, and the skill level required from operators.

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Pankaj Bhatt
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© © All Rights Reserved
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Download as DOCX, PDF, TXT or read online on Scribd
6 views

Production system

The document outlines the characteristics and types of production systems, emphasizing the organized nature of production aimed at transforming inputs into outputs while incorporating feedback for performance improvement. It details intermittent production systems, including job and batch production, as well as continuous production systems such as mass production, process production, and assembly line production, highlighting their advantages and limitations. Each production type is characterized by its operational flow, machinery usage, and the skill level required from operators.

Uploaded by

Pankaj Bhatt
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Production System

The production system has the following characteristics:


 Production is an organized activity, so every production system has an
objective.
 The system transforms the various inputs to useful outputs.
 It does not operate in isolation from the other organization system.
 There exists feedback about the activities, which is essential to control
and improve System performance.

1. Intermittent Production System


An intermittent production system is typified by the intermittent or
interrupted flow of material. It makes use of special purpose machines, and
produces components different in nature and in small quantities. Machine
ships, repair and maintenance shops, wildling shops, etc. are some of the
examples of intermittent production. Intermittent production can be
classified as
a) Job production
b) Batch production
a. Job Production
Job shop production are characterized by manufacturing of one or few
quantities of products designed and produced as per the specification of
customers within prefixed time and cost.
The distinguishing feature of this is low volume and high variety of products.
A job shop comprises of general-purpose machines arranged into different
departments. Each job demands unique technological requirements,
demands processing on machines in a certain sequence.

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⋆ High variety of products and low volume.
Characteristics of Job Shop Production

⋆ Use of general-purpose machines and facilities.


⋆ Highly skilled operators who can take up each job as a challenge

⋆ Large inventory of materials, tools, parts.


because of uniqueness.

⋆ Detailed planning is essential for sequencing the requirements of each


product, capacities for each work center and order priorities.

⋆ Because of general purpose machines and facilities variety of products


Advantages of Job Shop Production

⋆ Operators will become more skilled and competent, as each job gives
can be produced.

⋆ Full potential of operators can be utilized.


them learning opportunities.

⋆ Opportunity exists for creative methods and innovative ideas.

⋆ Higher cost due to frequent set up changes.


Limitations of Job Shop Production

⋆ Higher level of inventory at all levels and hence higher inventory cost.
⋆ Production planning is complicated.
⋆ Larger space requirements.
b. Batch production
Batch production is defined by American Production and Inventory Control
Society (APICS) - “as a form of manufacturing in which the job passes through
the functional departments in lots or batches and each lot may have a different
routing.”
It is characterized by the manufacture of limited number of products
produced at regular intervals and stocked awaiting sales.
Characteristics of Batch Production

⋆ When there is shorter production runs.


Batch production system is used under the following circumstances:

⋆ When plant and machinery are flexible.


⋆ When plant and machinery set up is used for the production of item in

⋆ When manufacturing lead time and cost are lower as compared to job
a batch and change of set up is required for processing the next batch.

order production.

⋆ Better utilization of plant and machinery.


Advantages of Batch Production

⋆ Promotes functional specialization.


⋆ Cost per unit is lower as compared to job order production.

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⋆ Lower investment in plant and machinery as compared to mass

⋆ Flexibility to accommodate and process number of products.


production.

⋆ Job satisfaction exists for operators.

⋆ Material handling is complex because of irregular and longer (possibly)


Limitations of Batch Production

⋆ Production planning and control is complex.


flows.

⋆ Work in process inventory is higher compared to continuous

⋆ Higher set up costs due to frequent changes in set up.


production.

2. Continuous production system


The manufacture of products requiring the sequential performance of
different processes on a series of multiple machines receiving the material
for manufacture through a closed channel. For example, continuous
production is generally conducted in the paper and chemical business.
a) Mass production
b) Process production
c) Assembly line production

⋆ Manufacture of discrete parts or assemblies using a continuous


a. Mass Production

⋆ Justified by very large volume of production.


process are called mass production.

⋆ The machines are arranged in a line or product layout.


⋆ Product and process standardization exists.
⋆ All outputs follow the same path.
⋆ Different types of products on a large-scale and stock them in

⋆ The goods are produced either with the help of a single operation or
warehouses until they are demanded in the market.

uses a series of operations.

⋆ Continuous flow of production


Characteristics of Mass Production

⋆ Limited work in progress


⋆ Supervision is easy, only a few instructions are required.
⋆ Materials are mostly handled by machines.
⋆ The flow of materials is continuous with no or little queuing.
Advantages of Mass Production

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⋆ Higher rate of production with reduced cycle time.
⋆ Higher capacity utilization due to line balancing.
⋆ Less skilled operators are required.
⋆ Low process inventory.
⋆ Manufacturing cost per unit is low.

⋆ Breakdown of one machine will stop an entire production


Limitations of Mass Production

⋆ High investment in production facilities.


line.

⋆ The cycle time is determined by the slowest operation.

b. Process continuous production


Production facilities are arranged as per the sequence of production
operations from the first operations to the finished product.
The items are made to flow through the sequence of operations through
material handling devices such as conveyors, transfer devices, etc.

⋆ Highly mechanized system for materials handling


Characteristics of Process Production

⋆ Low skilled labour and highly skilled technicians are required.


⋆ Almost no work in progress.
⋆ Production planning and scheduling can be pre decided.

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⋆ Entire production system is dedicated to produce only one type of
product.

⋆ Standardization of product and process sequence.


Advantages of Process Production

⋆ Higher rate of production with reduced cycle time.


⋆ Higher capacity utilization due to line balancing.
⋆ Manpower is not required for material handling as it is completely

⋆ Person with limited skills can be used on the production line.


automatic.

⋆ Unit cost is lower due to high volume of production

Line balancing (Heijunka)

⋆ Flexibility to accommodate and process number of products does not


Limitations of Process Production

⋆ Very high investment for setting flow lines.


exist.

⋆ Product differentiation is limited.

⋆ A production process that breaks the manufacture of a good into steps


c. Assembly Line production

that are completed in a pre-defined sequence.

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⋆ Assembly lines are the most commonly used method in the mass

⋆ They are able to reduce labor costs because unskilled workers could be
production of products.

easily trained to perform specific tasks. Rather than hire a skilled


craftsman to put together an entire piece of furniture or vehicle engine,
companies would hire a worker to only add a leg to a stool or bolt to a
machine.

The assembly line was first mechanized in the U.S. in 1797 by Eli Whitney,
Whitney began using the assembly line to manufacture muskets that had
interchangeable parts. Over a 2-year period, Eli's company built 10,000
muskets rifles for the U.S. government.

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