(5)manufacturing system
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Manufacturing System
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Manufacturing systems-contd
Begins with the selection of product & its expected volumeProduct can be a mechanical product or a chemical product
Product can be a standard product or a customised product
Standard products will have low variety & high volume. Customised products will have high variety & low volume.
1
2
Volume
V
ariety 1 Intermittent Production system
2 Continuous Production System
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Manufacturing systems-contd
ContinuousProduced Continuously
Product Produced for stock
Production process inflexible
Regular use of EquipmentOnly particular type
Large scale of production
Plg /control Operations simple & easy
Single set of instructions for OperationCapital investment is high
Unit production cost is low
More job security
Divisional type of organization
Staff of managerial ability & cood skills.
Storage needed at limited locations
Change in location isdifficult
Product & process standardised
Accuracy high
Intermittent1 Same product not produced Continuously
2 Product produced for order
3 Production process flexible
4 Equipments used for limited time5 Wide range of products
6 Smaller scale of production
7 Complicated & tedious Plg /control Opern
8 Detailed & many instructions for Opera
n
9 Capital investment may be low
10 Unit production cost is high
11Less job security
12 Functional type of organization
13Staff of high tech. skill & ability required
14 Storage needed at each operation
15Change in location is easy
16 Product & process not standardised
17 Accuracy Low
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Manufacturing systems-contd
Types of intermittent production system:
1. Job Production
2. Batch production
3. Project
Types of continuous production system:
1. Mass
2. Flow or assembly line
3. Process
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Features of Manufacturing systems
Intermittent Production:
Suitable for large variety of output
Each output takes different routes / operations,
Have different time requirement & operation sequence.Different outputs are called Batches or Lots
Characteristics :
Output variety large & volumes low Flexible in approach since uses general purpose
machines
Transformation process is organized around standard
operation ,each functional group is a specialist group Material handling depends upon Standard operation
Has high w.i.p inventory
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Features of Manufacturing systemsContinuous Production:
Workflow is continuous & all outputs are treated alike.
Output variety low & volumes large
Facilities are arranged in a linear sequence& consist of special
machines. Material movement is minimised.
Standard product is on a flow basis at a predetermined rate.
Mass poduction is carried on continuously for stock in
anticipation of demand Nos. & sequence of operations remain more or less same..
Material handling& positioning is mechanised mostly on
conveyer lines. Machine set up remains unchanged for a long time.
Machines performing specific operations can be handled bysemi-skilled operators.
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Continuous Production
Production line is characterised by fixed rate capacity.
Operating cycle time time required to convert raw material into finished product is relatively short.
Continuous production is most suited for process industry e.g.
chemicals, refineries, food processing Also applied toassembly industries like automobiles radio, fridge etc.
In continuous assembly operations :
Base frame of the product starts from stage 1 of the line & othercomponents/sub-assemblies added at subsequent stages s theproduct move forward. Thus the products grow on the line & istaken off at the final stage of the line.
In this system, investment in inventories are low.
System requires standard material, quantity estimates reliable.
Does not necessitates sub-storing.
PPC is relatively simplified,
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Features of Manufacturing systems
Continuous Production:Advantage:
Low cost per unit production.
Operations are simpler.Managerial control is simplified.
Disadvantage.
Difficult to adopt to a different product line & change in outputrate.
Breakdown results in line stoppage.
Line balancing responds to output rate of slowest work station.Tasks are repetitive & so monotones Process dehumanising.
Adversely affects workers morale..
High initial project cost, maintenance is expensive.
Obsolescence of the process used is a big problem