(5)manufacturing system

7/29/2019 (5)Manufacturing System

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Manufacturing System


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Manufacturing systems-contd

Begins with the selection of product & its expected volumeProduct can be a mechanical product or a chemical product

Product can be a standard product or a customised product

Standard products will have low variety & high volume. Customised products will have high variety & low volume.

1

2

Volume

V

ariety 1 Intermittent Production system

2 Continuous Production System


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ContinuousProduced Continuously

Product Produced for stock

Production process inflexible

Regular use of EquipmentOnly particular type

Large scale of production

Plg /control Operations simple & easy

Single set of instructions for OperationCapital investment is high

Unit production cost is low

More job security

Divisional type of organization

Staff of managerial ability & cood skills.

Storage needed at limited locations

Change in location isdifficult

Product & process standardised

Accuracy high

Intermittent1 Same product not produced Continuously

2 Product produced for order

3 Production process flexible

4 Equipments used for limited time5 Wide range of products

6 Smaller scale of production

7 Complicated & tedious Plg /control Opern

8 Detailed & many instructions for Opera

n

9 Capital investment may be low

10 Unit production cost is high

11Less job security

12 Functional type of organization

13Staff of high tech. skill & ability required

14 Storage needed at each operation

15Change in location is easy

16 Product & process not standardised

17 Accuracy Low


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Types of intermittent production system:

1. Job Production

2. Batch production

3. Project

Types of continuous production system:

1. Mass

2. Flow or assembly line

3. Process


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Features of Manufacturing systems

Intermittent Production:

Suitable for large variety of output

Each output takes different routes / operations,

Have different time requirement & operation sequence.Different outputs are called Batches or Lots

Characteristics :

Output variety large & volumes low Flexible in approach since uses general purpose

machines

Transformation process is organized around standard

operation ,each functional group is a specialist group Material handling depends upon Standard operation

Has high w.i.p inventory


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Features of Manufacturing systemsContinuous Production:

Workflow is continuous & all outputs are treated alike.

Output variety low & volumes large

Facilities are arranged in a linear sequence& consist of special

machines. Material movement is minimised.

Standard product is on a flow basis at a predetermined rate.

Mass poduction is carried on continuously for stock in

anticipation of demand Nos. & sequence of operations remain more or less same..

Material handling& positioning is mechanised mostly on

conveyer lines. Machine set up remains unchanged for a long time.

Machines performing specific operations can be handled bysemi-skilled operators.


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Continuous Production

Production line is characterised by fixed rate capacity.

Operating cycle time time required to convert raw material into finished product is relatively short.

Continuous production is most suited for process industry e.g.

chemicals, refineries, food processing Also applied toassembly industries like automobiles radio, fridge etc.

In continuous assembly operations :

Base frame of the product starts from stage 1 of the line & othercomponents/sub-assemblies added at subsequent stages s theproduct move forward. Thus the products grow on the line & istaken off at the final stage of the line.

In this system, investment in inventories are low.

System requires standard material, quantity estimates reliable.

Does not necessitates sub-storing.

PPC is relatively simplified,


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Features of Manufacturing systems

Continuous Production:Advantage:

Low cost per unit production.

Operations are simpler.Managerial control is simplified.

Disadvantage.

Difficult to adopt to a different product line & change in outputrate.

Breakdown results in line stoppage.

Line balancing responds to output rate of slowest work station.Tasks are repetitive & so monotones Process dehumanising.

Adversely affects workers morale..

High initial project cost, maintenance is expensive.

Obsolescence of the process used is a big problem

(5)manufacturing system

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