Manufacturing System

Manufacturing systems-contd
Begins with the selection of product & its expected volume Product can be a mechanical product or a chemical product Product can be a standard product or a customised product Standard products will have low variety & high volume. Customised products will have high variety & low volume.

Variety

1 2 Volume

1 Intermittent Production system 2 Continuous Production System

Manufacturing systems-contd
Intermittent 1 Same product not produced Continuously 2 Product produced for order 3 Production process flexible 4 Equipments used for limited time 5 Wide range of products 6 Smaller scale of production 7 Complicated & tedious Plg /control Opern 8 Detailed & many instructions for Operan 9 Capital investment may be low 10 Unit production cost is high 11Less job security 12 Functional type of organization 13Staff of high tech. skill & ability required 14 Storage needed at each operation 15Change in location is easy 16 Product & process not standardised 17 Accuracy Low

Continuous
Produced Continuously Product Produced for stock Production process inflexible Regular use of Equipment Only particular type Large scale of production Plg /control Operations simple & easy Single set of instructions for Operation Capital investment is high Unit production cost is low More job security Divisional type of organization Staff of managerial ability & cood skills. Storage needed at limited locations Change in location isdifficult Product & process standardised Accuracy high

Manufacturing systems-contd Types of intermittent production system: 1. Job Production 2. Batch production 3. Project Types of continuous production system: 1. Mass 2. Flow or assembly line 3. Process

Features of Manufacturing systems

Intermittent Production: Suitable for large variety of output Each output takes different routes / operations, Have different time requirement & operation sequence. Different outputs are called Batches or Lots Characteristics : Output variety large & volumes low Flexible in approach since uses general purpose machines Transformation process is organized around standard operation ,each functional group is a specialist group Material handling depends upon Standard operation Has high w.i.p inventory

Features of Manufacturing systems

Continuous Production: Workflow is continuous & all outputs are treated alike. Output variety low & volumes large Facilities are arranged in a linear sequence& consist of special machines. Material movement is minimised. Standard product is on a flow basis at a predetermined rate. Mass poduction is carried on continuously for stock in anticipation of demand Nos. & sequence of operations remain more or less same.. Material handling& positioning is mechanised mostly on conveyer lines. Machine set up remains unchanged for a long time. Machines performing specific operations can be handled by semi-skilled operators.

 Continuous Production
Production line is characterised by fixed rate capacity. Operating cycle time time required to convert raw material in to finished product is relatively short. Continuous production is most suited for process industry e.g. chemicals, refineries, food processing Also applied to assembly industries like automobiles radio, fridge etc. In continuous assembly operations : Base frame of the product starts from stage 1 of the line & other components/sub-assemblies added at subsequent stages s the product move forward. Thus the products grow on the line & is taken off at the final stage of the line. In this system, investment in inventories are low. System requires standard material, quantity estimates reliable. Does not necessitates sub-storing. PPC is relatively simplified,

Features of Manufacturing systems

Continuous Production:

Advantage:
Low cost per unit production. Operations are simpler. Managerial control is simplified.

Disadvantage.
Difficult to adopt to a different product line & change in output rate. Breakdown results in line stoppage. Line balancing responds to output rate of slowest work station. Tasks are repetitive & so monotones Process dehumanising. Adversely affects workers morale.. High initial project cost, maintenance is expensive. Obsolescence of the process used is a big problem