PRODUCTION

INDUSTRIAL PLANT & SAFETY

Alessandro Chiaraviglio

Concept of production
Production function is the part of an organization, which
is concerned with the transformation of a range of inputs
into the required outputs (products) having the requisite
quality level.
Production is defined as the step-by-step conversion of
one form of material into another form through chemical
or mechanical process to create or enhance the utility of
the product to the user.
Thus production is a value addition process. At each
stage of processing, there will be value addition.

INDUSTRIAL PLANT & SAFETY

PRODUCTION

Production system
The production system is that part of an
organization, 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.
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PRODUCTION

Production system: characteristics

The production system has the following

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

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PRODUCTION

Production system: a scheme

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PRODUCTION

Fundamental cycles of company

Raw materials
procurement

Delivery of
raw materials

Payment of
raw materials

Production of
finished product /
service

Sale of finished
product / service

Payment of
finished product /
service

PRODUCTIVE CYCLE

ECONOMIC CYCLE

CASH CYCLE

FINANCIAL CYCLE

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PRODUCTION

Goal of a production system

The objective of the production management is to produce goods and

services of Right Quality and Quantity at the Right time and Right
manufacturing cost.
1. Right Quality: The quality of product is established based upon the customers
need. The right quality is not necessarily being the best quality. It is determined
by the cost of the product and the technical characteristics as suited to the
specific requirements.
2. Right Quantity: The manufacturing organization should produce the products in
right number. If they are produced in excess of demand the capital will block up
in the form of inventory and if the quantity is produced in short of demand, leads
to shortage of products.
3. Right Time: Timeliness of delivery is one of the important parameter to judge the
effectiveness of production department. So, the production department has to
make the optimal utilization of input resources to achieve its objective.
4. Right Manufacturing Cost: Manufacturing costs are established before the
product is actually manufactured. Hence, all attempts should be made to
produce the products at pre-established cost, so as to reduce the variation
between actual and the standard (pre-established) cost.

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PRODUCTION

Productivity
Productivity is defined in terms of utilization of
resources, like material and labour. In simple
terms, productivity is the ratio of output to input.
For example, productivity of labour can be
measured as units produced per labour hour
worked.
Productivity can be improved by
1. controlling inputs,
2. improving process so that the same input yields
higher output,
3. by improvement of technology.
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PRODUCTION

Classification of production system

Production systems can be classified as Job-shop,
Batch, Mass and Continuous production systems.

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PRODUCTION

Job-shop
Job-shop production are characterised by
manufacturing one or few quantity 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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PRODUCTION

Job-shop

Job-shop Production is characterized by

1. High variety of products and low volume.
2. Use of general purpose machines and facilities.
3. Highly skilled operators who can take up each job as
a challenge because of uniqueness.
4. Large inventory of materials, tools, parts.
5. Detailed planning is essential for sequencing the
requirements of each product, capacities for each
work centre and order priorities.

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PRODUCTION

Job-shop

Advantages
1. Because of general purpose machines and facilities variety of
products can be produced.
2. Operators will become more skilled and competent, as each
job gives them learning opportunities.
3. Full potential of operators can be utilized.
4. Opportunity exists for creative methods and innovative ideas.

Limitations
1. Higher cost due to frequent set up changes.
2. Higher level of inventory at all levels and hence higher
inventory cost.
3. Production planning is complicated.
4. Larger space requirements.

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PRODUCTION

Batch
American Production and Inventory Control Society
(APICS) defines Batch Production as a form of
manufacturing in which the job pass 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.
Batch Production is characterized by:
1. Shorter production runs.
2. Plant and machinery are flexible.
3. Plant and machinery set up is used for the production of item in
a batch and change of set up is required for processing the next
batch.
4. Manufacturing lead-time and cost are lower as compared to job
order production.
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Batch
Advantages
1.
2.
3.
4.
5.
6.

Better utilisation of plant and machinery.

Promotes functional specialisation.
Cost per unit is lower as compared to job order production.
Lower investment in plant and machinery.
Flexibility to accommodate and process number of products.
Job satisfaction exists for operators.

Limitations
1. Material handling is complex because of irregular and longer
flows.
2. Production planning and control is complex.
3. Work in process inventory is higher compared to continuous
production.
4. Higher set up costs due to frequent changes in set up.

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Mass production

Manufacture of discrete parts or assemblies using a continuous process are

called Mass Production.
This production system is justified by very large volume of production. The
machines are arranged in a line or product layout. Product and process
standardization exists and all outputs follow the same path.
Mass Production is characterized by
1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production capacities and
output rates.
3. Large volume of products.
4. Shorter cycle time of production.
5. Lower in process inventory.
6. Perfectly balanced production lines.
7. Flow of materials, components and parts is continuous and without any back
tracking.
8. Production planning and control is easy.
9. Material handling can be completely automatic.

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PRODUCTION

Mass production

Advantages
1.
2.
3.
4.
5.

Higher rate of production with reduced cycle time.

Higher capacity utilisation due to line balancing.
Less skilled operators are required.
Low process inventory.
Manufacturing cost per unit is low.

Limitations
1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major change with the changes in the product
design.
3. High investment in production facilities.
4. The cycle time is determined by the slowest operation.

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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.
Continuous production is characterized by
1.
2.
3.
4.

Dedicated plant and equipment with zero flexibility.

Material handling is fully automated.
Process follows a predetermined sequence of operations.
Component materials cannot be readily identified with final
product.
5. Planning and scheduling is a routine action.
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Continuous production

Advantages
1.
2.
3.
4.

Standardization of product and process sequence.

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 automatic.
5. Person with limited skills can be used on the production line.
6. Unit cost is lower due to high volume of production.

Limitations
1. Flexibility to accommodate and process number of products
does not exist.
2. Very high investment for setting flow lines.
3. Product differentiation is limited.

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PRODUCTION

Other classification: push or pull

Classification based on supply chain management:
Push system. The push system computes
production schedules for all levels based on
forecasts of sales of end items. Once produced,
subassemblies are pushed to next level
whether needed or not.
Pull system. The basic mechanism is that
production at one level only happens when
initiated by a request at the higher level. That is,
units are pulled through the system by request.

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PRODUCTION

Definition: push or pull

Push Systems:
schedule work
releases based on
demand forecast.

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Pull Systems:
authorize work
releases based on
system status.

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Definition: push or pull

A push supply chain makes production and distribution
decisions based on forecasts (Build-to-stock)
A pull supply chain drives production and distribution by
customer orders (Build/Assembly-to-Order)
Material

Process

Intermediate
Inventory

Process

Finished
Goods

Deliver

Push
Push

Pull
Pull

Key concept: Location of the push/pull boundary (PPB)

(strategic inventory point)
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Comparison: push or pull

Advantages

Disadvantages

PUSH
Allows Managers to manage that
Can lead to large inventories
is, plan and control things
Requires intricate knowledge of
Production Times & Product Flow

Can generate large quantities of

scrap before errors are discovered

Can lead to economies of scale in

purchasing and production

Requires diligence to maintain

effective product flow

Allows for the planning and

completion of complex assemblies Requires maintenance of large
as sub-components are delivered and complex databases
only by scheduled need
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Comparison: push or pull

Advantages

Disadvantages

PULL
Limited and known Final Inventory

Every job is a High Stress Rush

order

Worker only consume their time &

Raw Materials on what is actually
needed

Balanced systems MUST be in

place

Quality MUST be High each

piece has a definite place to go
else immediate feedback is given

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Setup times will greatly impact

throughput
Any problem will lead to unhappy
customers (either internal or
external)
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