The document discusses different types of production systems including job shop, batch, mass, and continuous production. It provides details on the characteristics and limitations of each system.
The document discusses different types of production systems including job shop, batch, mass, and continuous production. It provides details on the characteristics and limitations of each system.
The document discusses different types of production systems including job shop, batch, mass, and continuous production. It provides details on the characteristics and limitations of each system.
The document discusses different types of production systems including job shop, batch, mass, and continuous production. It provides details on the characteristics and limitations of each system.
Introduction Topic One: What is meant by production?
❑ Production/operations management is the process, which
combines and transforms various resources used in the production/operations subsystem of the organization into value added product/services in a controlled manner as per the policies of the organization.
❑ It is that part of an organization concerned with transforming a
range of inputs into the required (products/services) with the requisite quality level. Meaning ❑ of production ❑ The Production function is that part of an organization, which is concerned with the transformation of a range of inputs into the required outputs (products) having the requisite quality level.
❑ Production is defined as the step-by-step conversion of one
form of material into another form through a chemical or mechanical process to create or enhance the utility of the product to the user. Also, it is defined as a process by which goods and services are created Production system
❑ The production system of an organization is that part, which
produces products of an organization.
❑ The Production system is defined as activity where resources,
flowing within a defined system, are combined and transformed in a controlled manner to add value in accordance with the policies communicated by management.
❑ It is shown in the following diagram,,
Figure (1): Production system Characteristics of Production system
The production system has the following characteristics:
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 does not 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. Classifications of Production system
The production system has the following classifications:
1. Job Shop 2. Batch 3. Mass Production systems 4. Continuous Production systems Each system will be explained as follows, Figure (2): Classifications of Production system 1. Job shop production
❑ Job shop production are characterized by manufacturing of few
quantity of products designed and produced as per the specification of customers within prefixed time and cost.
❑ It depend on producing low volume and high variety of
products.
❑ A job shop comprises of general-purpose machines arranged
into different departments. ❑ Each job demands unique technological requirements, demands processing on machines in a certain sequence.
The characteristics of this production system are:
1. High variety of products and low volume. 2. Use of general-purpose machines and facilities. 3. Highly skilled operators who can take up each job as a challenge because of uniqueness. 4. Large inventory of materials, tools, parts The limitations of a job-shop production system are :
1. Higher cost due to frequent setup changes.
2. Higher level of inventory at all levels and hence higher inventory cost. 3. Production planning is complicated. 4. Larger space requirements. 2. Batch production system
❑ Batch production is defined as a form of manufacturing in which
the job passes through the functional departments in lots or batches and each lot may have a different routing.
❑ It is characterized by the manufacture of a limited number of
products produced at regular intervals and stocked awaiting sales. Batch production system is used under the following circumstances: 1. When there is shorter production runs. 2. When plant and machinery are flexible. 3. When plant and machinery set up is used for the production of item in a batch and change of set up is required for processing the next batch. 4. When manufacturing lead time and cost are lower as compared to job order production. The limitations of a batch production system are : 1. Material handling is complex because of irregular and longer flows. 2. Production planning and control is complex. 3. Work in process inventory is higher compared to continuous production. 4. Higher set up costs due to frequent changes in set up. 3. Mass production system
❑ This production system is justified by very large volume of
production.
❑ The machines are arranged in a line or product layout. Product
and process standardization exists, and all outputs follow the same path. The characteristics of a mass production system are :
1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production capacities and output rates. 3. Large volume of products. 4. Shorter cycle time of production. 5. Lower in process inventory. 6. Perfectly balanced production lines. 7. Flow of materials, components and parts is continuous and without any back tracking. 8. Production planning and control is easy. 9. Material handling can be completely automatic. The limitations of a mass production system are :
1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major change with the changes in the product design. 3. High investment in production facilities. 4. The cycle time is determined by the slowest operation. 4. Continuous production system
❑ Production facilities are arranged as per the sequence of
production operations from the first operation to the finished product.
❑ The items are made to flow through the sequence of operations
through material handling devices such as conveyors, transfer devices, etc. The characteristics of a continuous production system are : 1. Dedicated plant and equipment with zero flexibility. 2. Material handling is fully automated. 3. The process follows a predetermined sequence of operations. 4. Component materials cannot be readily identified with the final product. 5. Planning and scheduling are routine actions.
The limitations of a continuous production system are :
1. Very high investment for setting flow lines. 2. 3. Product differentiation is limited.
