Different types of manufacturing

process
 PRODUCTION SYSTEMS
The production system of an organization is
that part, which produces products of an
organization.
It is that activity whereby resources, flowing
within a defined system, are combined and
transformed in a controlled manner to add
value in accordance with the policies
communicated by management.
 What is a Production System?
Production System are those activities of an
organization where
resources flowing within a defined system
are combined and transformed
in a controlled manner
to add value
in accordance to the policies communicated by
the management.
 Types of Production Systems
The types of production processes / systems are
classified on the basis of
Product / Output Variety and
Product / Operations / Output Volume

They are broadly classified as:

Continuous Production Process
Process / Flow Production
Mass Production
Intermittent Production Process
Batch Production
Job Shop Production
 Types of Production Systems
Production processes or manufacturing operations may
broadly be divided into two categories.
Made to stock production process
These firms make items that are completed and placed
in stock before customer order is received.

Made to order production process

These complete the end item only after receiving a
customer order.
This is because manufacturer cannot anticipate what
each customer wants.
 Types of Production Systems
There is yet another type of production process
The third type of production process is one where
The company produces standard modules and
assembles these modules
according to the specifications of a customer order

This type of production process is Assemble-to-Order

production process. E.g.
PVC window assemblers,
modular kitchen board assemblers, etc.
 Types of Production Systems
Another way to define the type of production process is
based on the extent to which a factory has the
flexibility to produce a variety of products.
This can be categorized as follows
Continuous Production System
Flow Production System
Mass Production System
Intermitted Production System
Batch Production System
Job-shop Production System
Project Production System
Continuous Manufacturing System
These are also referred to as Repetitive
Manufacturing Systems.
These are mass production facilities that
produce high volumes of the same products.
They are usually make-to-stock producers.
The manufacturing happens in Automated,
special-purpose equipments.
 Repetitive Manufacturing
WIP is low because the items move quickly in
the plant.
Examples are television, radio, and telephone
producers.
Product(s) follow the same path:
 Continuous flow (flow shop)
Some products flow
continuously through
a linear process.
These types of
operations are called
continuous flow (flow
shop) operations.
Usually the products
are not discrete
 Continuous flow (flow shop)
Continuous flow operations are sometimes also
called process type operations
(as opposed to discrete operations).
Examples are
Chemical plant,
Oil and Gas,
Petroleum refineries,
Sugar mills, etc.
 Process Production / Flow Production
When is it used: Advantages:
Dedicated plant and Standardization of product
equipment with zero and process sequence
flexibility Higher rate of production
Material handling is fully with reduced cycle time.
automated. Highest capacity utilization
Process follows a due to line balancing
predetermined sequence of Manpower is not required for
operations material handling.
Component material cannot Persons with limited skills can
be readily identified with final be used for production
product process.
Planning and scheduling is a Unit cost is low due to high
routine action volume of production .
Product differentiation is
limited.
Involves high initial
 Mass Production Process
When is it used: Advantage:
Standardization of product and Higher rate of production
process sequence with reduced cycle time.
Dedicated special purpose Higher capacity utilization
machines having high due to line balancing
production capacities and Less skilled operators are
output rates required.
Large volume of products Low process inventory
Shorter cycle time Manufacturing cost per unit is
Lower in process inventory low.
Limitations
Balanced production lines
Break-down of one machine
Material and parts flow is may stop entire production
continuous without
backtracking line.
Line layout needs major
Production planning and control
is easy changes with changes in
product design.
Material handling can be
completely automatic Higher investment in
production facilities
 Intermitted Production Process
In this type of production process
The volume of each product is low.
Generally produces make-to-order, custom products in
accordance with design supplied by the customer.
Each job may be unique and may require a special set of
production steps.
Further, each job may require a particular routing.
There are no standard routings.
Products may follow different paths.
Needs general-purpose production equipment
 Job Shop Production Process
Job shop production process are used in
woodworking shops,
metal fabrication shops, etc.
May require an inventory of a few type of the raw
materials.
BUT, here the largest percentage of the inventory
is Work in Process (WIP).
Work in Process is the inventory that accumulates
in between process stages.
Job Shop Production Process
 Job Shop Production Process
When is it used: Advantages:
High variety of products with low A large variety of products
volume can be produced with the
Use of general purpose machines and general purpose machines
facilities Operators become more
skilled and competent with
Highly Skilled Operators who take up
each job
each job as a challenge
Full potential of operators can
Large inventory of materials,tools and be utilized
parts Opportunity exists for
Detailed planning is essential for creative methods and
sequencing of each product innovative ideas.
Capacities for each work centers
and order priority Limitations:
Production planning is
complicated
Larger space requirement.
 Batch Manufacturing
Many manufacturing operations fall between
job shops and repetitive manufacturing.
These are called batch manufacturing.
Batch means a single production run
Batch size means the quantity produced in a
single production run.
It may be less than 100 units OR up to a few
1000 units.
 Batch Manufacturing
The batch manufacturing company makes a batch
of one product, then may switch over (set up) the
equipment and make a batch of another item.
Production equipment should be more flexible
than repetitive manufacturing and it is generally
less flexible than job shops.
Here, products having same or similar processes
may be grouped into a product family.
Examples are small hand tools (e.g., drill, screw
driver), and hand mixers.
 Batch Production Process
When is it used: Advantages:
There is a shorter production run Lower manufacturing lead time and
Plant and machinery are flexible cost as compared to job order
Every batch of production production process.
requires changes in the plant Better utilization of plant and
and machinery set-up. machinery
Limitations: Promotes functional specialization
Material handling is complex Lower investment in plant and
Production planning & control is machinery
complex Flexibility to accommodate and
High set-up cost due to frequent process number of products
changes in set ups. Job Satisfaction to operators
WIP inventory is higher than
continuous production process.
 Project type
A project is a highly flexible and low volume type
operation.
Usually the item to be produced stays in a fixed place
and all the resources come to it.
At the end of production, resources leave the place.
Examples are
ship construction,
bridge construction,
buildings and
large machines.
 Project type
Some types of service operations may also be called as
Projects.
These involve a team of people over a period of time
and then the people leave the project.
Example:
Developing a software package may be a project
type of service operation.