MANUFACTURING

SYSTEM
 INTRO. – MANUFACTURING SYSTEM
• Manufacturing is the use of machines, tools & labor to make things for use or
sale.

• It may refer to a range of human activity, from handicraft to high-tech, but

is most commonly applied to industrial production, in which raw materials
are transformed into finished goods on a large scale.

• Some finished goods may be forwarded to others, such as- household

appliances or automobiles are sold to wholesalers, who in turn sell them to
retailers, who then sell them to end users – the “customers”.
 MEANING : MANUFACTURING SYSTEM
Manufacturing is characterized by tangible outputs (products);

 Outputs that the customers consume overtime,

 Jobs that use less labor & more equipment,

 no consumer participation in the conversion process (in
production),
 sophisticated methods for measuring production activities &
 resource consumption as product are made.
 CHARACTERISTICS : MANUFACTURING SYSTEM
1. Production is an organized activity, so every production system has an
objective.

2. The system transforms the various Inputs to useful Outputs.

3. It doesn’t operate in Isolation from the other organization system.

4. There exists a feedback about the activities, which is essential to control

and improve system performance.
 TYPES OF MANUFACTURING SYSTEM

1. CONTINUOUS or FLOW PRODUCTION

SYSTEMS

2. INTERMITTENT PRODUCTION SYSTEMS

 TYPES OF MANUFACTURING SYSTEM

1. CONTINUOUS or FLOW PRODUCTION SYSTEMS

a) Mass Production Systems

b) Process Production System :
(i) Synthetic Production
(ii) Analytic Production
c) Assembly Lines
 TYPES OF MANUFACTURING SYSTEM

2. INTERMITTENT PRODUCTION SYSTEMS

a) Project
b) Job-Shop Production Systems
c) Batch Production Systems
CONTINUOUS or FLOW
PRODUCTION SYSTEMS
 TYPES OF MANUFACTURING SYSTEM

1. CONTINUOUS or FLOW PRODUCTION SYSTEMS

a) Mass Production Systems

b) Process Production System :
(i) Synthetic Production
(ii) Analytic Production
c) Assembly Lines
 1. CONTINUOUS OR FLOW PRODUCTION SYSTEMS

 Continuous production system is the specialized manufacture of identical

products on which the machinery & equipment is fully engaged.

 It is characterized by long-run production of identical or similar items

through the same sequences of operations or processing steps.

 The production facilities / centers are located adjacent to one another as

per the sequence of operations for an item, in order to reduce the material-
handling costs.
 In continuous or flow production, the plant, its equipment & layout are primarily designed to
manufacture the product in question.
 Flexibility in selection of products for manufacture is confined to minor modifications in
layout or designs of models.

 Example : automobiles, engines, household machinery, chemical plants, etc.

NOTE :-
A decision to switch over to a different kind of product may not only result in
extensive tooling, but also the basic changes in layout & equipment policy,
especially when special purpose machines & complex material system handling
are involved.
 (A) MASS PRODUCTION SYSTEMS
 In mass production, a large number of identical articles are produced, but inspite of advanced
mechanization & tooling, the equipment need not be specially designed for this type of article
only.

 Standardization of materials, machines, products & processes is the basic feature of mass
production.

 The greater the volume of mass production, the more would be the reduction in direct labor
cost per unit.

 Mass production system is employed where production is carried out without interruptions.

 Example : Coca Cola, Pepsi or any other food item also.

(B) PROCESS PRODUCTION SYSTEMS

• In this, process are inter-linked & production is carried on continuously

through a uniform & standardized sequence of operations.

• This type of production is used in bulk processing of Crude Oil into

Petroleum, Kerosene, Diesel Oil, etc.

i. Analytical Process
ii. Synthetic Process
1. ANALYTICAL PROCESS :

Here, a raw material is broken down into different products.

Example: crude oil is analyzed into gas , petrol, kerosene & diesel oil.

Gas

Raw Petrol

Crude Oil
Kerosene
Diesel Oil
2. SYNTHETIC PROCESS :
It involves the mixing of two or more materials to manufacture a product.

Example: lauric acid, myristic acid, plasmatic acid, stearic acid, linoleic
acids are synthesized to manufacture soap.

Lauric Acid

Myristic Acid
Finished Product (Soap)
Plasmitic Acid

Stearic Acid
Linoleic Acid
 (C) ASSEMBLY LINES
• It was first developed in the automobiles industry in U.S.A.

• Here, two or more components are combined to manufacture a

finished product.

• Assembly Line is particularly useful, when a limited variety of similar products is

to be produced, on a mass scale or in fairly large batches on a continuous basis.

• The design of assembly line involves– the proper balancing of technology &
other manufacturing facilities so as to develop a rational approach of optimization
of results.
 ASSEMBLY LINES

Component 1
Part 1
Component 2

Component 3 FINISHED
Part 2 PRODUCT
Component 4 Eg:- Fan
Component 5
Part 3
Component 6
INTERMITTENT
PRODUCTION SYSTEMS
 TYPES OF MANUFACTURING SYSTEM

2. INTERMITTENT PRODUCTION SYSTEMS

a) Project
b) Job-Shop Production Systems
c) Batch Production Systems
 2. INTERMITTENT PRODUCTION SYSTEMS
 Intermittent means something that starts (initiates) & stops (halts) at irregular (unfixed)
intervals (time-gaps).

 In this system, the goods are manufactured specially to fulfill orders made by Customers,
rather than for Stock.

 Here, the flow of material is intermittent or irregular.

 In this system, large varieties of products are produced.

 The design of these products goes on changing, according to the design & size of the
product.
FEATURES OF INTERMITTENT PRODUCTION SYSTEM

1. Flow of production is not continuous.

2. Variety of products are produced.
3. Volume of production is small.
4. General purpose machines are used.
5. Sequence of Operations changes as per the Design.
6. Production depends on Customer's orders.

Example : machine shops, hospitals, general office, etc.

 (A) PROJECTS
• Project Technology deals with one-of-a-kind products that are tailored to the
unique requirements of each customer.

• Since, the products can not be standardized, the conversion process must be
flexible in its equipment capabilities, human skills, & procedures.

• Here, in Project Production System, company accepts a single, complex order or

contract.

• The order must be completed within a given time-period & at an estimated

cost.
• Projects can be small, medium or of large size depending upon the number of tasks
involved.

• Once the project is completed, the resources deployed on the projects are re-
directed to a new project.

• Sometimes, large jobs can be treated as projects.

• For Example : Satellite launching can be considered as Project.

Whereas, manufacturing of the satellite is Job-Shop Production.

• Other Examples : Contract for Airports, Dams, Roads, Buildings, Ship Building, etc.
 (B) JOB-SHOP PRODUCTION SYSTEMS

Job, ‘one-off’, or ‘make complete’ are descriptions given to the organization

whereby, the complete task is handled by a single worker or group of
workers.

Here, in Job-Shop or Jobbing Production System, company accepts a

contract to produce either one or few units of a product strictly as per the
specifications given by the customer.

The product is produced within a given period & at a fixed cost.

The cost is fixed at the time of signing the contract.

 Examples : Services given by a Gold-Smith, Repair Shops, Tailoring Shops, Manufacturer
of special Machine Tools

Where for Instance,

 the hairdresser, who cuts, washes & perms the customer’s hair,
 the tailor who makes the entire outfit,

Another Example :
o In a printing shop, many different jobs go on at any one time; the press will be set-up to run
one job.

o When that has completed, the press will be set-up to run the next job.

o Meanwhile, the first job is routed to other areas where it is folded, kept in order, stapled,
trimmed, packed & transported.
FEATURES :
1. The Production of Items takes place in Small Lots.

2. Items are manufactured as per Customer’s Specifications.

3. Highly Skilled Labor is needed for Specialized Jobs.

4. There is Disproportionate Manufacturing Cycle Time.

Example: the Time needed to design the product may be more than the
manufacturing time.
 (C) BATCH PRODUCTION SYSTEMS
 Batch production is the manufacture of a number of identical articles either to meet a
specific order or to satisfy the continuous demand.
Here, the production of items takes place in lots or batches, where a product is
divided into different jobs.
 All jobs of one batch of production must be completed before starting the next batch
of production.

 In Batch production, there can be 3 types, namely :-

i. A batch produced only once.

ii. A batch produced repeatedly at irregular intervals, when the need arises.
iii. A batch produced periodically at known intervals, to satisfy continuous demand.
Example :
o Manufacturing of Drugs & Pharmaceuticals, etc.

FEATURES :-
1. The products are made & kept in stock, until their demand arises in the
market.
2. General purpose machines & handling equipment, which can do many
different jobs quickly are installed, because large varieties of items are to
be produced.
3. There is a possibility of large work-in-progress.
4. There is a need for detailed Production Planning & Control.