PRODUCTION

SYSTEMS

Submitted by
Kapil Arora
 Production Systems- Basics
DEFINITION SYSTEM & PRODUCTION
• Production systems are “transformation processes”—processes that transform System is an arrangement or assembly of inter-dependent processes which
resources into useful goods and services operates as to achieve (fulfill) some objective
• The transformation process typically uses common resources such as labor, capital (for Production can be explained as an act of either manufacturing or mining or
machinery and equipment, materials, etc.), and space (land, buildings, etc.) to effect a growing of goods (commodities) generally in bulk for trade.
change- called factors of production It is a process that puts intangible inputs like ideas, creativity, research,
• More specifically, Production managers have referred to them as the “five M’s”: men, knowledge, wisdom, etc. in use or action.
machines, methods, materials, and money

COMPONENTS OF PRODUCTION SYSTEMS TANGIBLE GOODS INTANGIBLE GOODS

Production systems consists of three main components- INPUT, CONVERSION PROCESS
&OUTPUT • Tangible goods have a physical • Intangible goods do not have a
existence & can be felt physical existence & can not be
/touched felt /touched
CONVERSION
INPUT • Consider an example of a
PROCESS OUTPUT • Consider an example from a
Men , Material,
Design, Planning, Product, Services manufacturing industry like a service industry that of a
Machine, Capital
Control, Maintenance Sugar Industry. software-development firm or
company.
• Here, sugarcane is first used as
an input, then the juice of • Here, initially, written program
• Input- include raw-materials, machines, man-hours, components or parts, drawing, sugarcane is processed through codes are used as an inputs.
instructions and other paper works. a conversion process, finally to These codes are then integrated
get an output known as a in some database and are
• Conversion Process- includes operations (actual production process). Conversion refined sugar (used for mass provided with a user-friendly
process also includes supporting activities, which help the process of conversion. consumption) interface through a conversion
The supporting activities include; production planning and control, purchase of raw- process.
materials, receipt, storage and issue of materials, inspection of parts and work-in-
progress, testing of products, quality control, warehousing of finished products, etc. • Finally, an output is made
available in form of an executable
• Output- includes finished products, finished goods (parts), and services application program.

CLASSIFICATION OF PRODUCTION SYSTEMS
Production systems can be classified as Job Shop, Batch, Mass and Continuous Production
systems
JOB SHOP PRODUCTION
• characterized by manufacturing of one or few
quantity of products designed and produced as
per the specification of customers within prefixed
time and cost.
• Low volume and high variety of products.
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.
Limitations
3. Higher cost due to frequent set up changes.
4. Higher level of inventory at all levels and hence
higher inventory cost.
Production Systems- Classification
BATCH PRODUCTION
• a form of manufacturing in which the job passes
through the functional departments in lots or
batches and each lot may have a different routing
• Limited number of products produced at regular
intervals and stocked awaiting sales.
Advantages
1. Cost per unit is lower as compared to job order
production.
2. Lower investment in plant and machinery.
3. Flexibility to accommodate and process number
of products.
Limitations
4. Material handling is complex because of
irregular and longer flows.
5. Production planning is complex.
RECENT CLASSIFICATION
• Flexible Manufacturing systems
• Quick Response Manufacturing
• Computer Integrated Manufacturing
• Concurrent Engineering
• Mass Customization
• Lean Manufacturing , Toyota Production System
• Canon Production System
• Electrolux Manufacturing System
• Kanban System
• CONVIP System
MASS PRODUCTION CONTINUOUS PRODUCTION
• Manufacture of discrete parts or assemblies using • Production facilities arranged as per the
a continuous process sequence of production operations from the first
• justified by very large volume of production operations to the finished product.
• Product and process standardization exists, and • Items flow through the sequence of operations
all outputs follow the same path. through material handling devices such as
conveyors, transfer devices, etc.
Advantages Advantages
1. Higher rate of production with reduced cycle 1. Higher rate of production with reduced cycle
time. time.
2. Less skilled operators are required. 2. Higher capacity utilization due to line balancing.
3. Low process inventory. 3. Manpower is not required for material handling
4. Manufacturing cost per unit is low. as it is completely automatic.
Limitations Limitations
5. Breakdown of one machine will stop an entire 4. Very high investment for setting flow lines.
production line. 5. Product differentiation is limited.
6. High investment in production facilities.