1

Production
Process Conversion
Process

INPUT PROCESS OUTPUT

Transformation
Process
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Manufacturing operations
Vs Service operations
Manufacturing

Assemblin
Forming Machining
g
Manufacturing operations Vs 3

Service operations
Manufacturing
Assemblin
Forming
Change Machining
g
the
shape ;
Castadd
No ,for/
ge,
removal
extrusio
n, stamp,
embossi
ng ,
coining,
Spinning
Manufacturing operations Vs 4

Service operations
Manufacturing
Assemblin
Forming Machining
g
Change the shape ; Metal
No add / removal
removal

Cast ,forge, extrusion,

stamp, embossing ,
Milling ,
coining, Spinning
drilling
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Machining Manufacturing Process

Manufacturing operations Vs 6

Service operations
Manufacturing

Forming Machining Assembling

Change the shape ; Metal Joining the
No add / removal
removal components

Milling ,
Cast ,forge, extrusion,
stamp, embossing ,
drilling , Welding,
coining, Spinning
EDM , soldering

ECM
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Services Operations

▰ Intangible
▰ Standard services & custom services
▰ Some deal with tangible product – distribution
systems
▰ Pure intangible : Travel , Legal advisory , Health
care .. Etc
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PRODUCTION SYSTEM

PRODUCT DESIGN

PROCESS DESIGN

PRODUCTION DESIGN
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Production system

▰ Production system, any of the methods used in industry to

create goods and services from various resources.
▰ BATCH SYSTEM
▰ CONTINUOUS SYSTEM
▰ PROJECT SYSTEM
▰ INTERMITTENT SYSTEM

PRODUCT DESIGN : Form and function of a product

What a How a
product product will
LOOK like ? perform ?
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PROCESS DESIGN

▰ The process used – overall sequence of operation

▰ imagining and creating objects meant for mass
production. Type of work
stations required
▰ Process Design is the act of transforming an
organization's vision, goals, and available Necessary
equipments
resources into a discernible, measureable means of
achieving the organization's vision.
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PRODUCTION DESIGN

▰ System design
▰ Designing products from the point of view of
producibility
▰ Ensure minimum production cost
▰ Conscious effort
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The Process – Production

System
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Make-to-order and Make-to-

stock
▰ Make-to-order :  
╺ Customer’s order is not manufactured until the order is received. This
allows customization to the exact specifications that the customer
requires.
╺ The work is “pulled” through the process when customer demand is
present.
╺ it takes time , Goods are made in small amounts, and may be more
expensive.

▰ Make-to-Stock :
╺ produced in anticipation of customer demand,
╺ made in larger amounts , put into storage , unit cost may be lower ,
chances of losses due to forecast error, excess inventory, obsolescence
or theft.
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PRODUCTION
SYSTEM
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PRODUCTION SYSTEM
▰ PROJECT :
▰ A one-time event, such as
construction of an apartment
building, or writing a book,
▰ Each of these projects have a
high degree of customization,
substantial use of resources, and
a complex set of related
activities.
▰ There is only a single output at
the end of the project.
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PRODUCTION SYSTEM
▰ JOB SHOP:
▰ produced is unique for each customer
▰ a make-to-order type of business where
production is intermittent
▰ based on the customers measurements and
preferences of materials and components.
▰ Examples include a small bakery -custom
wedding cakes, or a business that makes
custom guitars or bicycles
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PRODUCTION SYSTEM

▰ BATCH
▰ make groups of identical products on a regular basis = batch.
▰ The batch will progress through a set of steps to be completed
from the start to the end. An organization may have multiple
batches at different stages coming through the process. 
▰ less variety , equipment used will be relatively general
purpose , skilled and experienced Employees
▰ .Examples of products made using batch production are baked
goods, aircraft parts, clothing, and vaccines. An important
decision by these firms is how big the batch should be.
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▰ Repetitive
▰ This type of business produces products that are more
standardized in nature. Usually the output is high.
▰ The skill level of the employees is usually average because
the steps are highly standardized
▰ Often, these processes use flexible automation that allows
for customization such as the addition of upgraded features.
▰ Examples of a repetitive process include assembly lines such
as assembling automobiles or electronics, a carwash, or a
cafeteria line.
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▰ Continuous
▰ A very high volume of standardized product is produced. 
▰ The type of product being made is described as non-discrete.
▰ This means that these businesses do not produce individual
products, rather a product that is often a liquid or a product
such as sugar, gasoline, or steel.
▰ An example of this type of process is an oil refinery.
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CONTINUOUS PROCESS
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▰ Hybrids
▰ using mixtures of process types. 
▰ Mass Customization model of production. 
▰ combines low-cost high volume of output, but each and
every customer order is customized to the customers
specifications.
▰ Usually the use of computer-aided manufacturing systems
is what permits this customization. 
▰ the vehicle manufacturer that has dozens of customization
packages and paint options such that each vehicle is custom
for the purchaser.
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FLEXIBLE MANUFACTURING
SYSTYEM [FMS]

▰ Latest technique - operate without human operators 24

hours a day under computer control
▰ Manufacturing controlled by machines
▰ Robots are arranged in a manner so that it can handle
any type of parts which it has been designed for .

▰ Basic flexibility
▰ System flexibility
▰ Aggregate flexibility
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COMPUTER INTERGRATED
MANUFACTURING SYSTYEM
[CIM]

▰ Using computer information system – shared database

▰ Integration of product designing and process designing
[PDPD] , Production planning and control [PPC] and
Production Process [PP]
▰ Access database from pre existing design and modify them
as per requirement and also save them for future use
▰ CAD – Computer Aided Design
▰ CAM – Computer Aided Manufaturing
▰ CAE – Computer Aided Engineering