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Group 3

ICE BREAKER

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Project /

one

Continuou

s / many

Degree of repetitiveness

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The conversion process has to be flexible with general-

purpose equipment, adaptive human skill and innovative

procedures to suit the situation.

Characteristics

1. definite beginning & end

2. non-uniform requirement of resources

3. involvement of different agencies4. fixed position layout

5. high cost over runs

6. personnel problems

7. scheduling & control

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Job-shop system

This production system deals with manufacture of small

lots of a large variety of products, which are custom-

designed and built.Since each lot of products is unique, it manufacturing

process and routing through different sections of the

manufacturing facility will have general-purpose machines

and varied human skills.

Facilities are usually small and some equipment isoverloaded.

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Job-shop system

There are several patterns of flow speed is slow,

run lengths are short and rate of change is ratherslow.Owing to the variety of the jobs, routine is complex

and control system is taxing, calling for quick

responses, innovation and de-bottlenecking.

Examples: large turbo-generators, largeengines, boiler, processing, equipments, special

electronic equipment, shipbuilding etc.

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Characteristics

1. Small production runs2. discontinuous flow of materials

3. disproportionate manufacturing cycle time

4. general purpose machines & process layout

5. highly skilled labor

6. highly competent knowledgeable supervision

7. large WIP

8. limited functions of PPC

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Batch system

This is the manufacture of a number of identicalarticles, either to meet customer demand or to satisfy

continuous demand. When the lot size is larger than job shop, the facilities

are also of moderate scale. Several jobs are repeatedin large volume.

There are some dominant products but their

quantities are not so large as to warrant-dedicated

machines. Batch production system is geared to make a large

variety of products in varying volume with the help of

general-purpose machines and varied human skills.

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Characteristics

1. Short runs

2. Skilled labor in specific trades

3. Supervisor to possess knowledge of specific process4. Limited span of control

5. General purpose machines & process type layout

6. Manufacturing cycle time affected due to queues

7. Large WIP8. Flexibility of production schedules

9. Need to have PPC

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Continuous

The specialized manufacture of identical articles on which the

equipment is fully engaged. It is normally associated with large

quantities and with a high rate of demand.

There are two types of continuous production: Mass production

and Flow production.

Plant size has a very wide distribution, but most of the plants

are of small or medium size.

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Assembly-line system

When the product range is small and volumes are large,

assembly line production system is employed with

specialized equipment, specific manufacturing procedures

and human skills and management systems. Speed is high, run lengths are reasonably long .

There is a great deal of emphasis on productivityimprovements involving assembly line balancing, staffing

in the event of absenteeism etc.

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Characteristics Of Assembly Lines

1. Continuous flow of material

2. Special purpose machines

3. Product layout

4. Mechanized materials handling5. Low skilled labor

6. Short manufacturing cycle time

7. Easy supervision

8. Limited WIP9. Lesser flexibility in production schedules

10.Some of assembly line products are : TV ,Fridge, Washing

Machines ,Motor Cars

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Continuous Process Flow System

Process production is characterized by manufacture

of a single product and stocked in warehouse

awaiting sales.

Chemical plants, fertilizer manufacturing units and oil

refineries use continuous-flow p0roduction systems. Raw materials are processed through different stages in

a continuous flow in obtaining finished products, whichare packed as required. sugar , cement ,paper , milk

,coke etc

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Characteristics Of

Process Plants

1. Special purpose machines with built in controls

2. highly mechanized material handling

3. virtually zero manufacturing cycle time

4. low skilled labour

5. supervisor to be process specialist

6. negligible WIP

7. limited production planning & control functions

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Selection of manufacturing process

In reality , very few organizations use only one

process type in true sense. Generally , at least 2 or 3

process

Manufacturers of automobile , electric appliances , copiers

etc use batch production to manufacture components &

some subassemblies and flow production for final assemblyManufacturing process like a product has a life cycle .

Product starts with project formThen small batches in growing stageThen in maturity phase mass & flow

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project

continuous

Mass & flow

batch

Introduction ( useproject form )

Growth ( use

batch form )

Maturity( use

mass form )

Maturity ( use

process

form )