and Control

huiroduction of Production Planning

PRODUCTION SYSTEMS

1.5. PRODUCTION SYSTEMS

1.5.1. introduction

Production is the sequence of operations which transform the

transformation from
given materials into desired products. This
one form to another is carried out either by one ora combination of

different manufacturing processes.

A system is a logical arrangement of components (physical and

conceptual) designed to achieve particular objectives according to

a plan.

Inputs Outputs:
Materials

Labour

Machines Transformation or Products

Conversion process Services
Facilities

Energy
Information&Technology
Information 1 edback

concerning outputs for process output

Fig. 1.3. Productive systems as transformation process

A production system is the rame work within which the
conversion of input into output occurs. At the one end of the
production system are the inputs and at the other end outputs.
Inputs and outputs are inked by certain operations or processes
which impart value to the inputs and are called transformation

process.
A simplified transformation process is slhovn in Fig.1.3.
 Production Plunning ande
1.16 Contro
Production Systems
1.5.2. Types of
the
of the
production of the
standardisation nro.
volume and
According to classified as:
are
production systems
products, the
1. Job shop production,
2. Batch production,
and
3. Mass production,
or continuous
production.
4. Process

1. Job Shop Production

iuvolves the manufacturing of
of a
Meaning: Job or unit production
the customer's order. This is a 'special
single complete unit as per
Each job or product is different fromn
order type of production.
involved. The work is started only when
others and no repetition is
the organisation has orders on hand..
there are three types of
According to the regularity of manufacture,
job production:

1. A small number of pieces produced once.

when the
2. A small number of pieces produced intermittently
need arises.

number of pieces produced periodically at known time

3. A small
intervals.

Characteristics:
(i) High variety and low volume.
wider
(1) General purpose machines and equipment to perform
range of operations.

(1i) Flow of materials is not continuous i.e., it is intermittent.

(iv) Highly skilled operators and supervisors are required.

(v) Variable path material handling equipments are used.
 "oduction
Iniroduction ofProd Planning and Control 1.17
Merits:

) l involves comparalively small investment in machinery

and equipment.
I t is flexible and can be adapted easily to changes in product

design.
Demerits:

Very large work-in-process inventory.

) Difficut in planning, scheduling and coordinating the
productions of numerous components of wide variety.
Git) Highly skilled workforce is required.

Giv) Manufacturing cycle time is more.

Suitability: Job shop production is applicable where custom-made
products are to be produced on a small scale.

2. Batch Production

Meaning: Inthis type, the producis are made in small batches and
in large variety. Each batch contains identical items but every
batch is different from the others.
Three types ofbatch production are:
1. A batch produced only once.
2. A batch produced repeatedly at irregular intervals, when the
need arises.
3. A batch produced periodically at known intervals, to satisfy
continuous demand.
Characteristics:
)A large variety of products ate manufactured in lots or
batches.
i) Both general purpose machines (for producing parts) and
special purpose maclhines (for assembling the parts) are
used.
1.18 Production Planning and Contr,tr
intermittent.
(iii) Flow of material is

(iv) Plant layout is process type.

(v) Flexible material handling system.

Short production runs.
Merits:
machineries flexible.
(ii) Plant and
are

medium volume.
(iii) Medium variety and
Demerits: ) Large work-in-process inventory.
(i) More number of set-ups.
Workloads on various machines sections ar
(ii)
unbalanced.

(iv) Process and product planning is to be done f

each batch.
manufactured on ture
Suitability: Drugs, clothes, paints, parts
sheet metal presses are a few
lathes, forging machines and
examples of batch production.
3. Mass Production
of product or
Meaning: In this type of production, only one type
manufactured in large quantities.
maximum 2 or 3 types are
machines and
Standardisation of products, process, materials,
are the basic features
of this
uninterrupted .flow of materials the
offers economies of scale as
system. Mass production system
volume of output is large.
Characteristics:
(i) Low variety and high volume.
(ii) Flow of material is continuous.
(i) Special purpose machines are used. Ors
(iv) Mechanised material handling systems such as conveyo
are used.
(V) The machine capacities are balanced.
(vi) Degree of mechanisation or automatior is high.
Introduction of Production Planning and Control 1.19
Merits:
() It offers lowest cost of production.
i) Shorter cycle time.
(ii) Work-in-process is comparatively low.
(iv) Easier production planning and control.
(vRelatively lower skilled persons can manage work.
Demerits:
) Higher inventory of raw materials.
(i) Less flexibility of equipment and machines.
Suitability: Electronics, electricals, automobiles, bicycles and
container industries are a few examples of mass production
industries.

4. Process Production
Meaning: This type of production is used for manufactureofthose
items whose demand is continuous and high. Here single raw
material can be transformed into different kind of products at
different stages of the production processes. e.g., in processing of
crude oil in refinery one gets kerosene, gasolene, etc., at different
stage of production.
The characteristics, merits and demerits of continuous production
system are the same as that of the mass production system.
Suitability: The industries like paper, textiles, cement, chemicals,
automobiles, elc., are a few examples of continuous production
industries.
Note The job shop production and batch production are also known as
intermittent production systems. The mass production and process production are
termed as continuous production system.
Fig. 1.4 illustrates the types of production systems and their
respective layouts used.
 Production Planning and Control
L20
Fixed position layout

Process
High layout
Job
shop
Batch Product layout
production

Continuous
production

Low
Low 100 10,000 1,000,000 High

Production Quantity

levels of
Fig. 1.4. Types of production and layouts used for different
production quantity and product variety
T fDrndnction