types of production systems
TRANSCRIPT
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By Anuradha Gaikwad
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Production Process
An Activity whereby raw material is converted
into semi finished products and
thereby adds to the value of utility of products,
which can be measured as the difference
between the value of inputs and value of outputs.2
BIMAT
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Production function Encompasses the activities of
procurement, allocation and utilization of resources.
The main objective of production function is to produce the goods and services demanded by the customers in the most efficient and economical way.
Therefore efficient management of the production function is of utmost importance in order to achieve this objective. 3
BIMAT
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is a system whose function is to convert a set of inputs into a set of desired outputs.
LandBuilding
Goods Machines
and Labour capital
ServicesManagementMaterialOthers
Inputs Conversio
n Process
Outputs
Control
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1. Job Production System.
2. Batch or Intermittent Production.
3. Continuous Production.
4. Mass Production
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Herein one or few units of the products are
produced as per the requirement and
specification of the customer.
Production is to meet the delivery schedule
and costs are fixed prior to the contract.
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1. Space vehicles 2. Aircraft 3. Machine tools4. Special purpose
machines5. Tooling 6. Jigs 7. Fixtures
8. Custom clothing9. Prototype10. Large turbo
generators11. Material handling
machines12. Construction
equipment
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Irregular Small lots Flexible machines Skilled workers Very small quantities Specially made High variety low repetition Skills required are very broad
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Skilled jobber or team of jobbers complete the entire product
Fixed position or process layout Multi-skilled operatives One part of the task is completed before
next starts A project with a team which combines to
complete the whole is more complex Product routings vary widely
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Job is a unique product
Work is concentrated on a specific unit
supervision and inspection relatively simple
Specifications can change depending on the
customer demand
Operators become more skilled & competent
as each job gives them learning opportunity.10
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Utilisation of full potential of operators.
Opportunity to use innovative ideas and
creative methods.
Working on a single unit, coping with a
variety of tasks gives more satisfaction.
General purpose machines help in variety
production.11
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Under this system the goods are produced partly for inventory and partly for customer's orders.
E.g. components are made for inventory but they are combined differently for different customers.
Automobile plants, printing presses, electrical goods plant are examples of this type of manufacturing
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In this, limited quantities of each of the
different types of products are
manufactured on same set of machines.
Different products are produced
separately one after the other.
E.g., automobile parts, electrical goods,
etc. 13
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1. Shorter production runs.2. Plant and machinery set up is is changed
as per requirements of the batch of items.3. More number of set ups and hence high
cost.4. Amount of supervision is less compared to
job order.5. Plant and machinery are flexible.6. Manufacturing lead time and cost are
lower as compared to job order production.7. Higher level of work in process inventory.
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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 macinery.5. Flexibility to accommodate and process
number of products.6. Job satisfaction exists for operators.
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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. Longer production times.5. Higher set up costs due to frequent
changes in set up.6. Lower utilisation of production facilities
compared to mass production.16
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It refers to the production of standardized products with a standard set of process and operation sequence in anticipation of demand.
It is also known as mass flow production or assembly line production.
Associated with continuous production and high demand.
The system is suitable for oil refineries, cement manufacturing etc.
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1. Steel
2. Ores
3. Cloth
4. Pharmacy products
5. gases.
6. Chemicals
7. Petroleum products
8. Cement
9. Rubber
10. Paint
11. Paper processing
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1. Dedicated plant and equipment with zero flexibility.
2. Material handling is fully automated.3. Wet or dry product flow measurable by
weight or volume.4. Shorter lead-times.5. Component materials cannot be
readily identified with final product and the product cannot be disassembled.
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6. The end product is not naturally divisible and hence n additional step such as bottling or canning is needed to get the product into saleable units.
7. Larger investment and usually capital intensive units.
8. Process follows a predetermined sequence of operations.
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9. Maintenance is an important aspect.
10. Unit coat is lower due to high volume.
11. Planning and scheduling is a routine
action.
12. Persons with (semi-skilled) limited skills,
can be used on production line.
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1. Variations in raw materials quality due to different sources of supply.
2. Processing technology variations.3. Variations in yields of output.4. Demand for by-products and joint
products.5. Shelf life of raw materials.6. Product differentiation is limited.7. Plant availability depends on preventive
maintenance system.22
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Under this, the production run is conducted on a set of machines arranged according to the sequence of operations.
A huge quantity of same product is manufactured at a time and is stocked for sale.
Different products will require different manufacturing lines.
Since one line can produce only one type of product, this process is also called as line flow.
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1. Standardisation of product & process sequence and hence product (line) layout is recommended.
2. Dedicated special purpose machines having higher production capabilities & output rates.
3. Large volume of products.4. Shorter cycle time of production.5. Lower in process inventory.6. Perfectly balanced production lines.
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7. Flow of materials, components and parts
is continuous & without any backtracking.
8. Production planning and control is easy.
9. Extent of supervision required is less.
10. Material handling can be fully automated.
11. Unit per cost is low due to high volume.
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1. Higher rate of production with reduced cycle time.
2. Higher capacity utilisation due to line balancing.
3. Less skilled operator can man the process.
4. Low in process inventory.5. Production cost per unit will come down
due to economies of scale.
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1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major adjustment / changes with the changes in the product design.
3. High investment in production facilities.4. Supervision is general rather than specific.5. Work for operators is monotonous without
much challenge.6. The cycle time is determined by slowest
operation.
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Under this, the production run is conducted for an run is conducted for an indefinite period.
Identical products are produced in large numbers.
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High volumes and low variety Standard repeat products Highly capital intensive and automated Few changeovers Difficult and expensive to start and stop Product layout usually along conveyors or
pipes No idle time Operators at work stations perform tasks as it
passes through the workstation Line is dedicated to one product only Flexible continuous flow line may be capable
of switching over to a model or product variant
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Ease of using just in time technique Labour and production costs reduced due
to detailed planning Deviants in the line are spotted through
quality control techniques No rest between operators so work-in-
progress levels can be kept low Space storage is minimum Physical handling is minimum Investment is quickly converted into sales Control is easy 30
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Assembly line is industrial
arrangement of machines, equipment,
and workers for continuous flow of work
pieces in mass-production operations
First assembly line was introduced by
Henry Ford in 1908
Consists of sequence of work stations31
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It is the issue of assigning tasks to the work
station
Tasks may require different times
Assignment of tasks times to work stations
are unequal
This leads to idle time 32
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Assignment of tasks depends on demand rate
Depending on demand rate lines might be duplicated
Requires logical planning Distribute total job among the work
station so that all stations can complete their designed tasks at approximately same time
Split total assembly procedure into sub assemblies
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Demand is high duplicate entire line
Shortens the assembly line
May require more equipment and tooling
More tasks are assigned to a work station
Enriches work content
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