INTRODUCTION

TO MANUFACTURING
PROCESSES

MODULE -1

02-3-2021
 Manufacturing Methods
Manufacturing Methods are the various ways of producing finished goods
depending on the intensity of market demand & customer requirement.
Classification of Manufacturing Methods
Classification of Production Systems
Classification of Production Systems
Job shop
production Batch
production

Mass
production

Flow
production
Discrete Manufacturing
Discrete manufacturing is the process of producing distinct items.
Automobiles, Furniture's, Toys, Mobiles & Aircraft manufacturing
sectors are good examples of discrete manufacturing.

The resulting products are easily identifiable and differ greatly from
process-manufacturing where the products are undifferentiated for
example oil, natural gas and salt.

This kind of manufacturing is often characterized by

individual or separate unit production.

Units can be produced in low volume with very

high complexity or high volumes of low complexity.
Low volume/high complexity

Low volume/high complexity production results in the need for an extremely

flexible manufacturing system that can improve quality and time-to-market
speed while cutting costs.
High volume/low complexity
High volume/low complexity production puts high premiums on inventory control, lead
times and reducing or limiting materials costs and waste.
The processes deployed in discrete manufacturing are not continuous in nature. Each
process can be individually started or stopped and can be run at varying production rates.
The final product may be produced out of single or multiple inputs.

Producing a STEEL structure will need only one type of raw material - steel.
Producing a mobile phone requires many different inputs, The plastic case, LCD
display, the mother board, PVC keypad, sockets, cables are made from different
materials, at different places.
Process Manufacturing
Process manufacturing is the branch of manufacturing that is associated with
formulas and manufacturing recipes, and can be contrasted with Discrete
Manufacturing, which is concerned with bills of material and routing.

Process manufacturing like production of paper or petroleum refining, where the

end product is obtained by a continuous process or a set of continuous processes.

Simpler definition of Process manufacturing is once an output is produced by

this process, it cannot be distilled back to its basic components.
Process Manufacturing
Process Manufacturing
For instance consider a can of soda cannot be returned to its basic components
such as carbonated water, citric acid, Potassium benzoate, aspartame and other
ingredients.
A plastic card manufactured cannot be returned to its basic components like PVR
sheets, transparent sheets.
Where as a car or computer, on the other hand, can be disassembled and its
components, to a large extent can be returned to stock.
Repetitive Manufacturing

Repetitive manufacturing is period based planning and not based

on orders.

Normally same products will be manufactured over longer periods

of time.

Products will not change frequently.

A total quantity is produced according to a certain production rate

over a certain period of time.

Costs are collected periodically at a product cost collector.

Repetitive Manufacturing

It involves a steady flow and simplified routing through

production lines.

The routing of the individual products are very similar, and

also the components are often staged at the production lines
without reference to a particular order.

The confirmations (back flushes) are usually executed

periodically with no reference to an order (for example, all the
quantities produced in one shift).
Assemble to Order Manufacturing
Assemble to Order is a production approach where products are
not built until a confirmed order for products is received.

It is one of the oldest styles of manufacturing and is the most

appropriate approach used for highly customized or low volume
products.

This approach is considered good for highly configured products,

e.g. Automobiles, Air-crafts, Computer servers or for products
where holding inventories is very expensive, e.g. Shipbuilding
(YATCH Manufacturing), and is a demand driven production
approach where a product is scheduled and built in response to a
confirmed order received for it from a final customer.
Assemble to Order Manufacturing
Assemble to Order Manufacturing
The main advantages of the BTO approach in environments of
high product variety is the ability to supply the customer with the
exact product specification required, the reduction in sales
discounts and finished good inventory, as well a reduction in
stock obsolescence risk.
Job Production or One off Production
Job production, sometimes called jobbing or one-off production,
involves producing custom work, such as a one-off product for a
specific customer or a small batch of work in quantities usually less
than those of mass-market products.

Job production is most often associated with classical Craft

production, small firms (making railings for a specific house,
building/repairing a computer for a specific customer, making flower
arrangements for a specific wedding etc.) but large firms use job
production too.
Job Production or One off Production
Job Production or One off Production
Examples include:

• Construction of bridges
• Building a new factory
• Designing and implementing an advertising campaign
• Auditing the accounts of a large Public limited company
• Installing machinery in a factory
• Machining a batch of parts per a CAD drawing supplied by a
Customer

Fabrication Shops and machine shops whose work is primarily

of the job production type are often called job shops