group 3 production types
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Group 3
ICE BREAKER
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Project /
one
Continuou
s / many
Degree of repetitiveness
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The conversion process has to be flexible with general-
purpose equipment, adaptive human skill and innovative
procedures to suit the situation.
Characteristics
1. definite beginning & end
2. non-uniform requirement of resources
3. involvement of different agencies4. fixed position layout
5. high cost over runs
6. personnel problems
7. scheduling & control
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Job-shop system
This production system deals with manufacture of small
lots of a large variety of products, which are custom-
designed and built.Since each lot of products is unique, it manufacturing
process and routing through different sections of the
manufacturing facility will have general-purpose machines
and varied human skills.
Facilities are usually small and some equipment isoverloaded.
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Job-shop system
There are several patterns of flow speed is slow,
run lengths are short and rate of change is ratherslow.Owing to the variety of the jobs, routine is complex
and control system is taxing, calling for quick
responses, innovation and de-bottlenecking.
Examples: large turbo-generators, largeengines, boiler, processing, equipments, special
electronic equipment, shipbuilding etc.
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Characteristics
1. Small production runs2. discontinuous flow of materials
3. disproportionate manufacturing cycle time
4. general purpose machines & process layout
5. highly skilled labor
6. highly competent knowledgeable supervision
7. large WIP
8. limited functions of PPC
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Batch system
This is the manufacture of a number of identicalarticles, either to meet customer demand or to satisfy
continuous demand. When the lot size is larger than job shop, the facilities
are also of moderate scale. Several jobs are repeatedin large volume.
There are some dominant products but their
quantities are not so large as to warrant-dedicated
machines. Batch production system is geared to make a large
variety of products in varying volume with the help of
general-purpose machines and varied human skills.
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Characteristics
1. Short runs
2. Skilled labor in specific trades
3. Supervisor to possess knowledge of specific process4. Limited span of control
5. General purpose machines & process type layout
6. Manufacturing cycle time affected due to queues
7. Large WIP8. Flexibility of production schedules
9. Need to have PPC
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Continuous
The specialized manufacture of identical articles on which the
equipment is fully engaged. It is normally associated with large
quantities and with a high rate of demand.
There are two types of continuous production: Mass production
and Flow production.
Plant size has a very wide distribution, but most of the plants
are of small or medium size.
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Assembly-line system
When the product range is small and volumes are large,
assembly line production system is employed with
specialized equipment, specific manufacturing procedures
and human skills and management systems. Speed is high, run lengths are reasonably long .
There is a great deal of emphasis on productivityimprovements involving assembly line balancing, staffing
in the event of absenteeism etc.
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Characteristics Of Assembly Lines
1. Continuous flow of material
2. Special purpose machines
3. Product layout
4. Mechanized materials handling5. Low skilled labor
6. Short manufacturing cycle time
7. Easy supervision
8. Limited WIP9. Lesser flexibility in production schedules
10.Some of assembly line products are : TV ,Fridge, Washing
Machines ,Motor Cars
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Continuous Process Flow System
Process production is characterized by manufacture
of a single product and stocked in warehouse
awaiting sales.
Chemical plants, fertilizer manufacturing units and oil
refineries use continuous-flow p0roduction systems. Raw materials are processed through different stages in
a continuous flow in obtaining finished products, whichare packed as required. sugar , cement ,paper , milk
,coke etc
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Characteristics Of
Process Plants
1. Special purpose machines with built in controls
2. highly mechanized material handling
3. virtually zero manufacturing cycle time
4. low skilled labour
5. supervisor to be process specialist
6. negligible WIP
7. limited production planning & control functions
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Selection of manufacturing process
In reality , very few organizations use only one
process type in true sense. Generally , at least 2 or 3
process
Manufacturers of automobile , electric appliances , copiers
etc use batch production to manufacture components &
some subassemblies and flow production for final assemblyManufacturing process like a product has a life cycle .
Product starts with project formThen small batches in growing stageThen in maturity phase mass & flow
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project
continuous
Mass & flow
batch
Introduction ( useproject form )
Growth ( use
batch form )
Maturity( use
mass form )
Maturity ( use
process
form )