Manufacturing process management article

Manufacturing processes

1. MANUFACTURING SYSTEM
•PROJECT PRODUCTION -Single assignment within the
given period and estimated expenditure.
•JOBBING PRODUCTION -Units are produced to customer’s
requirement within the given date & fixed price.
•BATCH PRODUCTION -Limited quantity of each type is
manufactured at a time.
•MASS & FLOW PRODUCTION -Production run is
conducted on a single machine or line and several products are
manufactured at a time.
•PROCESS PRODUCTION -Production run is for a
continuous period.

2. FACTORS FOR SELECTING
MANUFACTURING SYSTEM
•Effect of Volume-Higher volume -Continuous Process
•Effect of Variety-Higher Variety -batch production
•Capacity of the Plant-High fixed cost for continuous
process, High variable cost for intermittent process
•Flexibility -Related to variety
•Lead Time -higher lead time requires product to be produced
( in batches ) and stocked.
•Efficiency -Efficiency is higher for mass production.
•Environment -market preferences as well as environment
forces changes in technology.

3. PROJECT PRODUCTION
•Short Life Cycle ( finite )
•Non -Uniform requirement of resources
•Involvement of different agencies
•Fixed position layout
•High cost overruns
•Personnel problem ( Temporary, remote location)
JOBBING PRODUCTION
•Small production runs
•Discontinuous flow of material
•higher design, planning and manufacturing cycle time.
•Flexible plan and equipment. ( Functional layout)
•Highly skilled specialized labour.
•Higher WIP
•Higher involvement of PPC.

4. BATCH PRODUCTION
Manufacture of limited number of products in many
numbers at regular interval and stocked in warehouses
as F.G. or F.P.
•Short Runs & frequent changes of set up.
•Labour is skilled in one specific process.
•Supervisors have knowledge of a specific process & extent of
supervision is lower than in Jobbing.
•Layout of Plant & Machinery is arranged for maximum
flexibility and is generally process layout..
•Machines and handling Equpts. Are general purpose capable of
variety of operations and easy set up.
•Manufacture cycle time is lower than Jobbing.
•WIP is higher due to variety, imbalances & queueing.

5. BATCH PRODUCTION
•Multiple machine capable of same process gives flexibility to
production schedule.
•Material control and Tools control is exercised using routine
replenishment.
•Detailed operational layouts and route sheets are prepared for
each part of product.
•Loading and scheduling needs to be more detailed for each
machine.
•Progress tracking using progress card is very important.
•Expediting is necessary due to imbalances.
•May require multiple handling of same product.
•Higher storage space.

6. MASS & FLOW PRODUCTION
•Several number of standard product produced and stocked in the
warehouses.
•Flow of material is continuous with little or no queuing
•SPM are used laid on the basis of product layout.
•Comapratively less material handling & is mostly mechanised by
conveyors and transfer machines.
•Relatively low skilled labour is required.
•Short manufacturing cycle time.
•Easier supervision only at the start of the job.
•Less WIP as the production is balanced.
•Interruptions and breakdown seriously affect production .
•Maintenance and provision of stand by operators become major
function.

7. Process Production
•Single product manufactured and stocked. No flexibility.
•The layout of plant,location of services and storage, position of
cranes, conveyors is to facilitate unidirectional material flow.
•SPM’s with built in controls and regulate inputs and measure
output are employed.
•Manufacturing cycle time is almost zero.
•Production labour is semi-skilled with skilled technicians.
•Supervisor is highly qualified with considerable knowledge of
process.
•WIP is very small as flow is continuous.
•Material control & Inventory control functions are of crucial
importance.
•Tools control function is almost absent.
•Process planning and scheduling is very simple.
•Progressing and expediting are extremely simplified.

8. •Most organisations use 2 or more forms to produce components
and the final product.
•The conversion process follows a life cycle.
–Introduction stage-Project form withGPM to keep low
fixed cost. High labour cost.
–Growth Stage -GPM organised for Batch Production
–Maturity stage -More and more sub-processes organised
on SPM’s using Flow production to reduce cost per unit.
•Break-Even-Analysis is used to select optimal manufacturing
process.
MANUFACTURING SYSTEM SELECTION