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Types of Production Systems
Types of Production Systems
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Ê 6roduction 6rocess
Ê 6roduction function
Ê Encompasses the activities of procurement,
allocation and utilization of resources.
Ê The main objective of production function is to
produce the goods and services demanded by
the customers in the most efficient and
economical way.
Ê Therefore efficient management of the
production function is of utmost importance in
order to achieve this objective.
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Ê is a system whose function is to convert a set
of inputs into a set of desired outputs.
Conversion
Inputs Outputs
6rocess
Land
Building Goods
Machines and
Labour capital Services
Management
Material Control
Others
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3. Continuous 6roduction.
4. Mass 6roduction
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Ê Irregular
Ê Small lots
Ê Flexible machines
Ê Skilled workers
Ê Specially made
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Ê Skilled jobber or team of jobbers complete the
entire product
Ê Fixed position or process layout
Ê Multi-skilled operatives
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Ê [nder this system the goods are produced
partly for inventory and partly for customer's
orders.
Ê E.g. components are made for inventory but
they are combined differently for different
customers.
Ê Automobile plants, printing presses, electrical
goods plant are examples of this type of
manufacturing
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½. Shorter production runs.
2. 6lant and machinery set up is is changed as per
requirements of the batch of items.
3. More number of set ups and hence high cost.
4. Amount of supervision is less compared to job
order.
5. 6lant and machinery are flexible.
6. Manufacturing lead time and cost are lower as
compared to job order production.
7. igher level of work in process inventory.
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½. Material handling is complex because of
irregular and longer flows.
2. 6roduction planning and control is complex.
3. Work in process inventory is higher compared
to continuous production.
4. Longer production times.
5. igher set up costs due to frequent changes in
set up.
6. Lower utilisation of production facilities
compared to mass production.
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Ê It refers to the production of standardized
products with a standard set of process and
operation sequence in anticipation of demand.
Ê It is also known as mass flow production or
assembly line production.
Ê Associated with continuous production and high
demand.
Ê The system is suitable for oil refineries, cement
manufacturing etc.
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½. Steel 6. Chemicals
3. Cloth 8. Cement
5. gases. ½ . 6aint
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½. Dedicated plant and equipment with zero
flexibility.
2. Material handling is fully automated.
3. Wet or dry product flow measurable by weight
or volume.
4. Shorter lead-times.
5. Component materials cannot be readily
identified with final product and the product
cannot be disassembled.
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½. Variations in raw materials quality due to
different sources of supply.
2. 6rocessing technology variations.
3. Variations in yields of output.
4. Demand for by-products and joint products.
5. Shelf life of raw materials.
6. 6roduct differentiation is limited.
7. 6lant availability depends on preventive
maintenance system.
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Ê [nder this, the production run is conducted on
a set of machines arranged according to the
sequence of operations.
Ê A huge quantity of same product is
manufactured at a time and is stocked for sale.
Ê Different products will require different
manufacturing lines.
Ê Since one line can produce only one type of
product, this process is also called as line flow.
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½. Breakdown of one machine will stop an entire
production line.
2. Line layout needs major adjustment / changes
with the changes in the product design.
3. igh investment in production facilities.
4. Supervision is general rather than specific.
5. Work for operators is monotonous without much
challenge.
6. The cycle time is determined by slowest
operation.
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Ê igh volumes and low variety
Ê Standard repeat products
Ê ighly capital intensive and automated
Ê Few changeovers
Ê Difficult and expensive to start and stop
Ê 6roduct layout usually along conveyors or pipes
Ê No idle time
Ê Operators at work stations perform tasks as it passes
through the workstation
Ê Line is dedicated to one product only
Ê Flexible continuous flow line may be capable of
switching over to a model or product variant
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Ê Ease of using just in time technique
Ê Labour and production costs reduced due to
detailed planning
Ê Deviants in the line are spotted through quality
control techniques
Ê No rest between operators so work-in-progress
levels can be kept low
Ê Space storage is minimum
Ê 6hysical handling is minimum
Ê Investment is quickly converted into sales
Ê Control is easy 3
BIMAT
unequal
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BIMAT
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Ê Assignment of tasks depends on demand rate
Ê Depending on demand rate lines might be
duplicated
Ê Requires logical planning
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