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Production System 1

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12 views24 pages

Production System 1

Uploaded by

rayarakuladavid1
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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PRODUCTION

SYSTEM
SCHEMATIC
PRODUCTION
SYSTEM
SIMPLIFIED PRODUCTION
SYSTEM
• Senior managers: make long-range
strategic decisions about products
and services

• Middle managers: carry out the


programs and plans of senior
management

• Operational managers: monitor the


firm’s daily activities
JOB SHOP
PRODUCTION
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.
EX:

•ELECTRONIC EQUIPMENT •CERAMIC •SOFTWARE


MANUFACTURING MANUFACTURING
CHARACTERISTICS

1. High variety of products and low volume.


2. Use of general purpose machines and facilities.
3. Highly skilled operators who can take up each job as a challenge because
of uniqueness.
4. Large inventory of materials, tools, parts.
5. Detailed planning is essential for sequencing the requirements of each
product, capacities for each work centre and order priorities.
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.
3. Full potential of operators can be utilised.
4. Opportunity exists for creative methods and innovative ideas.

Limitations
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.
B ATC H
PRODUCTION
B AT C H P R O D U C T I O N
• 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 characterised by the manufacture of limited number of products produced at regular
intervals and stocked awaiting sales.
Characteristics
Batch production system is used under the following circumstances:
1. When there is shorter production runs.
2. When plant and machinery are flexible.
3. When plant and machinery set up is used for the production of item in a batch and change of set up is
required for processing the next batch.
4. When manufacturing lead time and cost are lower as compared to job order production.
•Textile Ind
•Furniture
•Electrical goods
•News papers
•Books
•Coca cola Bottel
Advantages
Following are the advantages of batch production:
1. Better utilisation of plant and machinery.
2. Promotes functional specialisation.
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.
MASS PRODUCTION
MASS PRODUCTION
Manufacture of discrete parts or assemblies using a continuous process are 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.
Characteristics
1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production capacities and output rates.
3. Large volume of products.
4. Shorter cycle time of production.
5. Lower in process inventory.
6. Perfectly balanced production lines.
7. Flow of materials, components and parts is continuous and without any back tracking.
8. Production planning and control is easy.
9. Material handling can be completely automatic.
•Car
•Glass
•Micro chips
CONTINUOUS
PRODUCTION
•Production facilities are arranged as per the sequence of production operations
from the first operations to the finished product. The items are made to flow
through the sequence of operations through material handling devices such as
conveyors, transfer devices, etc.
Characteristics
Continuous production is used under the following circumstances:
1. Dedicated plant and equipment with zero flexibility.
2. Material handling is fully automated.
3. Process follows a predetermined sequence of operations.
4. Component materials cannot be readily identified with final product.
5. Planning and scheduling is a routine action.
Some common continuous processes are the following:
• Oil refining
• Chemicals
• Synthetic fibers
• Fertilizers
• Pulp and paper
• Blast furnace (iron)
• Metal smelting
• Power stations
• Natural gas processing
• Sanitary waste water treatment
• Continuous casting of steel
• Rotary kilns for calcining lime or cement
• Float glass
• Biscuit production
EXAMPLES OF 4 BASIC TYPE PRODUCTION SYSTEMS

Most Processes are somewhere between Job shop and Flow shop

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