Production Process

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all the production processes

1. P RODUCTION P ROCESS Presented By: Amandeep Punias Consulting

2. WHAT PRODUCTION SYSTEM IS ? • Production System are those activities of any organization where : Resources flowing within a defined system Are combined and transformed In a controlled manner To add value In accordance to the policies communicated by the management.

3. CHARACTERSTICS OF A PRODUCTION SYSTEM Production is an organized activity, so every production system has an objective. The system transforms various I/P to Valuable O/P. Doesn’t operates in isolation from other Organizational systems : Integrated system it is. There exists a feedback about the activities , which is essential to control and improve system performance.

4. TYPES OF A PRODUCTION PROCESS Types of Production Process is broadly Divided into : Made to Stock Production Process Firms produces their products and stores in plan before receiving any customer order Made to Order Production Process Completes the end Products only after Receiving a confirmation from the customer. Because their may be different variants for the products that a customer requires

5. TYPES OF A PRODUCTION PROCESS Another way to define Production Process is based on extent to which a factory has the flexibility to produce a variety of products. Continues Production System Flow Production system Mass Production System Intermittent Production System Batch Production System Job Shop Production System Project Production System

6. TYPES OF A PRODUCTION PROCESS

7. CONTINUOUS MANUFACTURING SYSTEM These are also referred to as Repetitive Manufacturing system. These are mass Production facilities that produces high volume of same product. They are usually MTS producers. The manufacturing happens in automated , Special purpose equipment.

8. REPITITIVE MANUFACTURING SYSTEM Major Characteristics : WIP is low because items move quickly in the plant. Products follow the same path. For Ex. : Televisions , Telephone , Mobiles , Automobile Parts.

9. CONTINUOUS FLOW (FLOW SHOP) Major Characteristics : Products flow continuously through a Linear Process. Usually products are not Discrete. Also called Process Type Operations. For Ex. : Chemical Plant Oil &Gas Sugar mills. Petroleum Refineries

10. MASS PRODUCTION PROCESS WHEN IT IS USED ? Standardization of products and sequence. Dedicated SPMs having high production capacities and O/P. Large volume of products. Shorter Cycle Time. Lower in Process Inventory. Balanced Production Lines. Material and parts flow is continuous without back tracking. Material Handling can be Fully automated.

11. MASS PRODUCTION PROCESS ADVANTAGES : Higher rate of Production with reduced Cycle Time. Higher Capacity Utilization due to Line Balancing. Less skilled Operators are required. Low Process Inventory. Manufacturing cost per unit is low.

12. MASS PRODUCTION PROCESS LIMITATIONS : Breakdown of one W ork C enter may stop entire production line. Line Layout required major changes with changes in Product Design. Higher Investment in production facilities.

13. INTERMITTED PRODUCTION PROCESS MAJOR CHARACTERSTICS : The volume of each product is low. Generally produces MTO , customized products in accordance with design supplied by the customer. Each job may be unique and may requires a special production setup. Each job may require a particular routing. There are no standard routings. Products may follow a different paths. Needs general purpose production equipment.

14. JOB SHOP PRODUCTION PROCESS MAJOR CHARACTERSTICS : May require an inventory of few types of RM. Largest amount of Inventory is on WIP. WIP is Work in process -: an inventory that accumulates in between Process stages.

15. JOB SHOP PRODUCTION PROCESS WHEN IT IS USED ? High variety of products with low Volume. Use of General Purpose machines and facilities. Highly skilled operators who take up their job as a challenge. Large inventory of materials , tools and parts. Detailed planning is necessary for sequence of each product , for every work center and Order priority.

16. JOB SHOP PRODUCTION PROCESS ADVANTAGES : A large variety of products can be manufactured using General purpose Machines. Operators become more skilled and competent with every passing Job done. Full potential of operators can be utilized. Opportunity exists for creative methods and innovative ideas. LIMITATIONS : Production Plan is complicated. Larger Space required.

17. BATCH MANUFACTURING PROCESS MAJOR CHARACTERISTICS : Manufacturing Operations that falls in between Job Shop and Repetitive M anufacturing are BATCH Manufacturing. Batch means Single Production run. Batch size means the qty. produced in single production run. Manufacturing industries setup for one batch and after completion have to switch to another batch. Production equipment should be more flexible than repetitive manufacturing but less than Job Shop manufacturing. For Ex. : hand tools , hand mixers , books etc.

18. BATCH MANUFACTURING PROCESS WHEN IT IS USED : When there is Shorter Production runs. Plant and Machinery are flexible. Every Batch of production requires changes in plant and machinery set up.

19. BATCH MANUFACTURING PROCESS ADVANTAGES : Lower manufacturing Lead time and cost as compared to Job Order Production process. Better utilization of plant and machinery. Promotes functional specialization. Lower investment in plant and machinery. Flexible to accommodate and process number of products. Job satisfaction to operators.

20. BATCH MANUFACTURING PROCESS LIMITATIONS : Material Handling is complex. Production planning and control is complex. High set up cost due to frequent changes in set ups. WIP Inventory is higher than Continues Production Process.

21. PROJECT MANUFACTURING PROCESS MAJOR CHARACTERISTICS : A project is highly flexible and low volume type operation. Usually the item to be produced stays in a fixed place and all the required resources comes to it. At the end of production, resources leaves the place. For Ex. : Ship construction Bridge Construction Buildings and large machinery.

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