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Types of production systems

Factors Influencing Process Choices

Volume: Average quantity of the products produced in a manufacturing system

Low volume: Turnkey project management firms such as L&T and BHEL High volume: Consumer non-durable and FMCG sector firms, Automobile, Chemical Processing Mid-volume: Consumer durables, white goods and several industrial products

Variety: Number of alternative products and variants of each product that is offered by a manufacturing system
Variety of product offerings is likely to introduce variety at various processes in the system; alternative production resources, materials, and skill of workers (Titan ,Telco)

Flow: Flow indicates the nature and intensity of activities involved in conversion of components and material from raw material stage to finished goods stage

Relationship between volume and variety

Volume

Variety

Mass Production Petrochemicals, Automobile

Mid volume Mid variety Motor Manufacturing Pharmaceuticals

Project Organisations Turnkey Project Execution

Processes & Operations Systems

Available Alternatives

Three types of flows occur in operating systems:

Continuous Intermittent Jumbled

Types of industries

Basic Industries

Manufacturing

Services

Project

Discrete

Process

Paper Manufacturing
An example of process industry

Logs and chips of wood stored

Crushing of logs and chips

Processing of the wood

Preparatory
Drying the wood pulp Refining the Wood pulp Cleaning & Bleaching

Pulp making
Stretching Paper rolling Cutting Final packing

Paper making

Continuous Flow System

Mass production in discrete manufacturing

In discrete manufacturing various components are manufactured in discrete fashion and the final product is obtained through an assembly process
In a mass production system, the volume of production is very high and the number of variations in the final product is low
Examples:
Automobile and two wheeler manufacturers,

Manufacturers of electrical components such as switches and health care products such as disposable syringes

The entire manufacturing is organised by arranging the resources one after the other as per the manufacturing sequence (known as product line structure)

Intermittent Flow System

Characterised by mid-volume, mid-variety products/services Increases the flow complexities Flow and capacity balancing are difficult but important
Process industries use batch production methods Discrete industries use alternative methods of designing layout issues

Capacity Estimation is hard Production Planning & Control is complex

Jumbled Flow System

Occurs on account of non-standard and complex flow patterns characteristic in certain systems
Highly customised items customer orders for one or a few

Examples
turnkey project executor such as BHEL or L&T customised manufacturing systems such as PCB fabricators, sheet metal fabricators, tool room operators and printing and publishing

Operational complexity arising out of jumbled flow is high

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Types of Production systems

Job Shop Type of Production

Flow Continuous Production

Types of Production Systems

Batch Type of Production

Mass Production

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Types of Production Systems Job Shop Type of Production

as per Customer demand, e.g. heavy m/c s, low volume high variety. Use of general purpose m/cs Highly skilled operators Large inventory of material, tools, parts.

Detailed planning required.

Limitations high cost, production planning is complicated

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Batch Type of Production:

Lot Production of similar items job passes through the functional departments in lots or batches. E.g : medicines.

Shorter production runs.

Plant and machinery are flexible. Better utilization of plant and machinery Limitations production planning becomes complex.

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Mass Production :
manufacture of discrete parts and accessories using a continuous process is called mass production, Demand pattern known, Standard product, Large batches. Dedicated assembly lines. lines, E.g :TV

Higher rate of production. Higher capacity utilization. Less skilled operators are required. Manufacturing cost per unit is low. Limitations ; breakdown of one m/c will stop entire prodn line. High investment.

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Flow /Continuous Production :

production facilities are arranged as per sequence of operations. Material is made to flow through sequence of e.g. Cement, Petrol/Diesel

Dedicated plant and machinery with Zero flexibility. Material handling is fully automated. Planning and scheduling is routine action.

High volume of production.

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Manufacturing Reference Model

Low volume D I S C R E T E
JOB/ASSEMBLY Machine-Tools Farming Equipments Shutters Jewelry BATCH/MIX Food Beverages, Wine Dairy Products Pharmaceuticals Paint

HIGH VOLUME/ REPETITIVE Electronic Components Spinning Mills Batteries Tyres

PROCESS/FLOW Refineries Glass Graphite Paper Mills Steel Fertilizers

P R O C E S S

High Volume

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Product Process Matrix

Low Volume Low Standardisation One of a kind Jumbled Flow (Job Shop) Disconnected Line Flow (Batch) Connected Line Flow (Assembly Line) Continuous Flow
.

Multiple Products Low Volume

High Volume Few Major Products High Standardisation Higher Volume Commodity Products

Satellite Launch Vehicle

None

Machine Tools

Auto electric parts

None

Polyethylene

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Manufacturing Strategies
raw materials components semi finished finished goods
eng prod prod prod

make-to-stock

s assemble-to-order u p p make-to-order l i e engineer-to-order r

standard customer driven

c u s t o m e r