Rutuja.

Mahindrakar BE Printing
PPPC Assignment Unit 1 (6009)

Q. Based on following types of products, categories them into proper production system. State
the salient features of that production system along with limitations if any.
1. Paper mill
2. Newspaper printing
3. Biscuit manufacturing
4. Spare parts for some machine
5. Petroleum products

Ans :
Production System: -
The production system of an organization is that part, 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. A simplified production system is shown above. 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.
 Classification of production systems: -
1. Job Shop Production
*Newspaper printing classified under job shop production.
*Job shop production are characterized by manufacturing of 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.
*Manufacturing of one or few number of a single product stickily to customer specification
within given period and fixed price pre-decided.
 Small production run
 Discontinuous flow of material.
 General purpose machine and process layout.
 Highly skilled labor
 Highly competent supervision capable of planning and taking independent decision.
 Advantages: -
following are the advantages of job shop production:
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: -
Following are the limitations of job shop production:
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.

2. Batch Production
*Biscuit manufacturing and spare parts for some machine classified under batch
production.
*Batch production is defined by American Production and Inventory Control Society
(APICS) “as 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.” It is
characterized by the manufacture of limited number of products produced at regular
intervals and stocked awaiting sales.
*Limited number of products per batch and many number of batches being produced after
periodic interval.
*Batch production is used to identical products in specified, predetermined “batches”.
*It can vary from tens to thousands of products.
*A key feature is the flexibility of the tooling, machinery and workforce to enable fast
turnaround of products.
*This can easily be adapted to manufacture different products.
*Batch production often makes use of flexible manufacturing systems (FMS) to enable
companies to be competitive.
*Batch production results in lower unit cost than one off production.
*More likely to be used for seasonal goods or products with a fixed life.
*Batch production will be used by high-street retailers as fashion changes so frequently
* Things like: Home interior products (inspired by a trend), decorated dresses and fashion
items.
 Short production run and frequent set up changes.
 Skilled labor in specific trade.
 Competent supervision.
 Limited span of control more supervision required when batches are small.
 General purpose machine and process layout.
 Long waiting periods.
 Large work in progress.
 Needs production planning and control.
 Advantages: -
Following are the advantages of batch production:
1. Better utilization of plant and machinery.
2. Promotes functional specialization.
3. Cost per unit is lower as compared to job order production.
4. Lower investment in plant and machinery.
5. Flexibility to accommodate and process number of products.
6. Job satisfaction exists for operators.
 Limitations: -
Following are the limitations of batch production:
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.

3. Mass Production: -
*Manufacture of discrete parts or assemblies using a continuous process is 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 products are produced in high volume.
*Mass production makes use of efficient automated manufacturing processes and a largely
unskilled workforce.
*Mass produced products are designed to follow mass market trends, so the product
appeals to a wide national and international target market.
*Production planning and quality control (QC) enables the manufacture of identical
products.
*Production costs are kept as low as possible so that the product will provide value for
money.
*Mass products will include things like, pens, pencils, electronic products, and many more
everyday items.
*It is a cheap method of production because materials can be bought in large numbers and
a large number can be made quickly.
 Continuous flow of material.
 Special purpose machine and product layout Mechanize material handling.
 Low skilled labor.
 Short or fixed manufacturing cycle time. Easy supervision.
 Limited work in progress. Lesser flexibility in schedule.
 Advantages: -
Following are the advantages of mass production:
1. Higher rate of production with reduced cycle time.
2. Higher capacity utilization due to line balancing.
3. Less skilled operators are required.
4. Low process inventory.
5. Manufacturing cost per unit is low.
 Limitations: -
Following are the limitations of mass production:
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.
4. Continuous Production: -
*Continuous production is a flow production method used to manufacture, produce, or
process materials without interruption. Continuous production is called a continuous
process or a continuous flow process because the materials, either dry bulk or fluids that
are being processed are continuously in motion, undergoing chemical reactions or subject
to mechanical or heat treatment. It can also be said as a variation of flow production is
continuous production. Here materials flow continuously through a process, and the
product is produced continuously. Good examples are oil refining, the manufacture of
detergents and the manufacture and printing of newsprint.
*Continuous production is used to manufacture standardized mass-produced.
products that meets every day mass-market needs. Production will run 24 hours a day, 7
days a week, 365 days a year.
*Continuous production is used to make products that are always needed and never change.
*This type of production is highly automated and uses machines that can run continuously
for long periods of time with breaks only for maintenance.
*Used for drinks bottles, cans, wine bottles, egg boxes, petrol. (Any product you can think
off that is constantly being used in the masses)
*More likely to manufacture products in their millions.

 Advantages: -
Following are the advantages of continuous production:
1. Standardization of product and process sequence.
2. Higher rate of production with reduced cycle time.
3. Higher capacity utilization due to line balancing.
4. 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: -
Following are the limitations of continuous production:
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.
 Factors affecting the choice of production process: -
1. Effect of volume/ variety.
2. Capacity of plant.
3. Lead time.
4. Flexibility and efficiency.