Manufacturing Systems / Methods

Manufacturing Systems / Methods

 The combination of operations and

activities required to create goods and
services is known as manufacturing
system or manufacturing method.
 Factors Influencing Choice of
Manufacturing System
 Volume / Quantity

 Capacity of the plant

 Variety of products

 Lead time

 Efficiency

 Environment
 Classification of Manufacturing System

 Project Production

 Jobbing Production

 Batch Production

 Mass and Flow Production

 Process Production
 Project Production
 Project production is characterized by
complex sets of activities that must be
performed in a particular order within
the given period and within the
estimated expenditure.
 For example ships, locomotive, aircraft,
construction of dams, roads, buildings,
shopping malls etc.
 Characteristics of Project Production

 Definite beginning and definite end

 Non uniform requirement of resources
 Involvement of different agencies
 Fixed position layout
 High cost overruns
 Personnel problems
 Scheduling and control
 Jobbing Production
 Jobbing production is characterized by the
manufacture of one or few numbers of a
single product designed and manufactured
strictly to customer’s specifications, within
the given period and within the price fixed
prior to the contract.
 For example manufacturers of cranes,
furnaces, generators, pressure vessels,
boilers, hydraulic machines, JCB machines,
heat exchanger, turbines etc.
 Characteristics of Jobbing Production
 Small production runs
 Discontinuous flow of materials
 Disproportionate manufacturing cycle time
 General purpose machines and process layout
 Highly skilled labour
 Highly competent and knowledgeable supervision
 Large WIP
 Limited functions of production, planning and
control
 Batch Production
 Batch production is characterized by the
manufacture of a limited number of a
product (but many such quantities of
different products) produced at regular
intervals and stocked in warehouses as
finished goods (or finished parts) awaiting
sales (or withdrawal for assembly).
 For example industries such as
pharmaceuticals, paints, chemicals, switch
gears, heavy motor vehicles etc.
 Characteristics of Batch Production
 Short production runs
 Skilled labour in specific trade
 Supervisor to possess knowledge of a
specific process
 Limited span of control
 General purpose machines and process
type of layout
Cntd…
Characteristics of Batch Production
 Less materials handling
 Manufacturing cycle time affected
due to queues
 Large WIP
 Flexibility of production schedules
 Need to have production, planning
and control
 Mass and Flow Production

 Mass as well as Flow Production are

characterized by the manufacture of
several number of standard products
produced and stocked in the
warehouses as finished goods
awaiting sales.
 Mass Production
 The goods under mass production are
manufactured either through a single
operation or a series of operations on
one machine.
 For example plastic goods, metals and
ceramics products, hardware etc.
 Flow Production
 Goods under flow production are
manufactured by a series of operations on
different machines, arranged as per
sequence of operations.

 For example automobiles, refrigerators,

radios, TV, electric fans, domestic
appliances etc.
Characteristics of Mass and Flow Production

 Continuous flow of material

 Special purpose machines and product type
layout
 Mechanized material handling
 Low skilled labour
 Short manufacturing cycle time
 Easy supervision
 Limited WIP
 Lesser flexibility in production schedules
 Process Production

 Process production is characterized by

the manufacture of a single product
produced and stocked in the
warehouses awaiting sales.
 For example sugar, steel, cement,
paper, coal, refineries etc.
 Characteristics of Process Production
 Special purpose machines
 Highly mechanized material handling
 Virtually zero manufacturing cycle time
 Low skilled labour
 Supervisor to be process specialist
 Negligible work in progress
 Limited production planning and control
functions
 Mass &
Factors Project Jobbing Batch Process
Flow

Quantity

Manu.
Cycle time

Material
handling

Control &
Supervisio
n

WIP
Inventory
 Mass &
Factors Project Jobbing Batch Process
Flow

Quantity Single Few Limited Many Infinite

Manu. Virtually
Longest Longer Considerable Short
Cycle time zero

Material
Highest Higher Considerable Negligible Nil
handling

Highly
Technical
Control & technical Negligibl
&
Supervisio & Limited Less e
knowledge
n knowledg
able
eable

WIP
Highest Higher Considerable Negligible Nil
Inventory
Any Questions?
Thank You…
Prepared by: Dr. K. M. Rahman
Associate Professor
Sinhgad Institute of Management,
Vadgaon, Pune