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Types of production systems

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Relationship between volume and variety

Volume Variety

MassProduction

Petrochemicals,Automobile

ProjectOrganisations

Turnkey ProjectExecution

Mid volumeMid variety

Motor ManufacturingPharmaceuticals

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Processes & Operations SystemsAvailable Alternatives

Three types of flows occur in operatingsystems:

Continuous Intermittent Jumbled

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Types of industries

BasicIndustries

Manufacturing

Discrete Process

Services Project

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Paper ManufacturingAn example of process industry

Logs and chipsof wood stored

Crushing of logs and chips

Processing of the wood

Cleaning &Bleaching

Refining theWood pulp

Drying thewood pulp

StretchingPaper rolling

CuttingFinal packing

Paper making

Pulp making

Preparatory

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Continuous Flow SystemMass production in discrete manufacturing

In discrete manufacturing various components aremanufactured in discrete fashion and the final product isobtained through an assembly process

In a mass production system, the volume of production is veryhigh and the number of variations in the final product is low Examples:

Automobile and two wheeler manufacturers,

Manufacturers of electrical components such as switches and health careproducts such as disposable syringes

The entire manufacturing is organised by arranging theresources one after the other as per the manufacturing

sequence (known as product line structure)

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Intermittent Flow System

Characterised by mid-volume, mid-varietyproducts/servicesIncreases the flow complexities

Flow and capacity balancing are difficult butimportant Process industries use batch production methods Discrete industries use alternative methods of

designing layout issuesCapacity Estimation is hardProduction Planning & Control is complex

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Jumbled Flow SystemOccurs on account of non-standard and complex flow

patterns characteristic in certain systems Highly customised items customer orders for one or a few

Examples turnkey project executor such as BHEL or L&T customised manufacturing systems such as PCB

fabricators, sheet metal fabricators, tool room operators andprinting and publishing

Operational complexity arising out of jumbled flow ishigh

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Types of Production systems

Types of Production

Systems

Job ShopType of

Production

Batch Typeof

Production

MassProduction

FlowContinuousProduction

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Types of Production SystemsJob Shop Type of Production

as per Customer demand, e.g. heavy m/c s,

low volume high variety.

Use of general purpose m/cs

Highly skilled operators

Large inventory of material, tools, parts.

Detailed planning required.Limitations high cost, production planning iscomplicated

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Batch Type of Production:

Lot Production of similar items job passesthrough the functional departments in lots or batches. E.g : medicines.

Shorter production runs.

Plant and machinery are flexible.

Better utilization of plant and machinery

Limitations production planning becomescomplex.

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Mass Production :

manufacture of discrete parts and accessories usinga continuous process is called mass production,Demand pattern known, Standard product, Largebatches. Dedicated assembly lines. lines, E.g :TV

Higher rate of production. Higher capacity utilization. Less skilled operators are required. Manufacturing cost per unit is low. Limitations ; breakdown of one m/c will stopentire prodn line.High investment.

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Flow /Continuous Production :

production facilities are arranged as per sequenceof operations. Material is made to flow throughsequence of e.g. Cement, Petrol/Diesel

Dedicated plant and machinery with Zeroflexibility.

Material handling is fully automated.

Planning and scheduling is routine action.

High volume of production.

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Low volume

High Volume

DI

SCRETE

P

ROCESS

Manufacturing Reference Model

JOB/ASSEMBLYMachine-ToolsFarming EquipmentsShuttersJewelry

HIGH VOLUME/REPETITIVE

ElectronicComponentsSpinning MillsBatteriesTyres

BATCH/MIXFoodBeverages, WineDairy ProductsPharmaceuticals

Paint

PROCESS/FLOWRefineries

GlassGraphitePaper MillsSteelFertilizers

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Product Process MatrixLow Volume

Low StandardisationOne of a kind

Multiple ProductsLow Volume

Few Major ProductsHigher Volume

High VolumeHigh StandardisationCommodity Products

ContinuousFlow

Connected Line

Flow (AssemblyLine)

DisconnectedLine Flow

(Batch)

JumbledFlow

(Job Shop)

Satellite LaunchVehicle

Machine Tools

Auto electricparts

PolyethyleneNone

None

.

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make-to-order

assemble-to-order

make-to-stock

suppli

er

eng prod prod prod

raw materials components semi finished finished goods

standard customer driven

engineer-to-order

custom

er

Manufacturing Strategies