Products sewn clothing are manufactured on a limited scale and is proportional to the number of orders received from customers. Here, sewing is not done continuously. It is intermittent. Different types of products can be produced by the use of these machines. Product depends on customer orders. The order must be completed within a certain period of time and at an estimated cost. Consider making a boat. Such products are never manufactured in large quantities.
Labor, facilities and other resources focus on these products. Therefore, each product can be treated as a project, which requires the sequencing of certain activities, either in series or simultaneously. Examples of project production flows mainly include the construction of airports, roads, buildings, shipbuilding, dams, etc. Characteristics of project production flows: 1. A resource requirement varies with the production phases. Many agencies are involved and their jobs are interrelated.
Delays take place at the end of the project. As routing and programming changes, inspection is required. In the job production flows, the company accepts a contract to produce one or a few units of a product strictly according to the specifications given by the customer. The product is produced within a certain period and at a fixed cost.
This cost is fixed at the time of signing the contract. Examples of such job production flows include services provided by clothing workshops, repair shops, manufacturers of special machine tools, etc.
Characteristics of jobbing production flows: 1. The production of items takes place in small batches. Items are manufactured according to customer specifications. Highly skilled labor is needed for specialized jobs 4.
There is a disproportionate manufacturing cycle time. In batch production flows, the production schedule is decided according to specific orders or is based on demand forecasts. Here, the production of items takes place in lots or lots. A product is divided into different jobs. All jobs in a production batch must be completed before starting the next production batch. Examples of batch production flows include, manufacture of drugs and pharmaceuticals, medium and heavy machinery, etc.
Characteristics of batch production flows batch instruction: 1. Products are manufactured and stored until demand arises. General-purpose machines and equipment are installed. There is a possibility of major work in progress. You need detailed production planning and control. Therefore a standard set of processes and sequences of the process can adopt. Thus continuous or flow production refers to the manufacturing of large quantities of a single or at most a very few varieties of products with a standard set of processes and sequences.
The mass production is carried on continuously for stock in anticipation of demand. The continuous system, however, is very rigid and if there is a fault in one operation the entire process is disturbed. Due to continuous flow, it becomes necessary to avoid piling up of work or any blockage on the line.
Unless the fault is cleared immediately, it will force the preceding as well as the subsequent stages to be stopped. Moreover, it is essential to maintain stand by equipment to meet any breakdowns resulting in production stoppages.
Thus investments in machines are fairly high. This production refers to the manufacturing of standardized parts or components on a large scale. Mass production system offers economies of scale as the volume of output is large.
Quality of products tends to be uniform and high due to standardization and mechanization. In a properly designed and equipped process, individual expertise plays a less prominent role.
Production is carried on continuously through a uniform and standardized sequence of operations. Highly sophisticated and automatic machines are used. Process production is employed in the bulk processing of certain materials.
The typical processing Industries are fertilizers plants, petrochemical plants, and milk dairies which have highly automated systems and sophisticated controls. They are not labor-intensive and the worker is just an operator to monitor the system and take corrective steps if called for.
On the basis of the nature of the production process, flow production may classify into Analytical and Synthetic Production. Assembly line a type of flow production which is developed in the automobile industry in the USA. A manufacturing unit prefers to develop and employ an assembly line because it helps to improve the efficiency of production.
In an assembly line, each machine must directly receive material from the previous machine and pass it directly to the next machine. Machine and equipment should be arranged in such a manner that every operator has free and safe access to each machine. Space should be provided for free movement of forklifts, trucks, etc.
In instances such as these, no single sequence pattern of operations is appropriate, so the relative location of the operation must be a compromise that is best for all inputs considered together. In the industries following the intermittent production system, some components may be made for inventory but they are combined differently for different customers. The finished product is heterogenous but within a range of standardized options assembled by the producers.
Since production is partly for stock and partly for consumer demand, there are problems to be met in scheduling, forecasting, control, and coordination. The intermittent system is much more complex than continuous production because every product has to be treated differently under the constraint of limited resources.
The intermittent system can be-effective in situations which satisfy the following conditions:. Each job or product is different from the other and no repetition is involved.
The product is usually costly and non-standardised. Customers do not make a demand for exactly the same product on a continuing basis and therefore production becomes intermittent. Each product is a class by itself and constitutes a separate job for the production process.
Shipbuilding, electric power plant, dam construction, etc. It is flexible and can adapt easily to changes in product design. Location change.
Capital invested. Now let's distinguish intermittent and continuous production system. Nature of product : In intermittent production system , goods are produced based on customer orders and not for stocking.
In continuous production system , goods are produced based on demand forecast and for stocking. Flexibility of process : In intermittent production system, production process is flexible. The product design goes on changing.
In continuous production system, production process is not flexible. It is standardized. The same product is manufactured continuously. Scale of production : In intermittent production system, goods are produced on a small scale, so there is no economies of scale. In continuous Production System, goods are produced on a large scale, so there are economies of large-scale production. Per unit cost : In intermittent production system, cost per unit may be higher because production is done on a small-scale.
In continuous production system, cost per unit may be lower because production is done on large-scale.
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