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Types of Production Systems -I

Types of Production Systems -I

Continuous Production

What is continuous production?

The manufacture of products requiring the sequential performance of different processes on a series of multiple machines receiving the material for manufacture through a closed channel. For example, continuous production is generally conducted in the paper and chemical business.

types of production systems

Characteristics

1. Dedicated plant and equipment with zero flexibility.

2. Material handling is fully automated.

3. Process follows a fixed sequence of operations.

4. Component materials cannot be readily identified with final product.

5. Planning and scheduling is a routine action.

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Benefits

1. Standardisation of product and process sequence.

2. Higher rate of production with decreased cycle time.

3. Higher capacity utilisation due to line balancing.

4. Manpower is not required for material handling as it is completely automatic.

5. Person with limited skills can be used on the production line.

6. Unit cost is lower due to high volume of production.

Limitations

1. Flexibility to accommodate and process number of products does not exist.

2. Very high investment for setting flow lines.

3. Product differentiation is limited.

Mass Production

What is mass production?

The manufacture of a product on a large scale. The mass production of items is often done by using an assembly line, or another efficient means of production. The process is often carefully determined, to try to produce the greatest quantity of items while using the fewest resources (such as labor and/or time).

Mass production has become popular since the assembly line became prominent in the 1900s, although the process embodies principles of efficiency that have been around much longer.

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Characteristics:

1. Standardisation 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.

Benefits

1. Higher rate of production with reduced cycle time.

2. Higher capacity utilisation due to line balancing.

3. Less skilled operators are required.

4. Low process inventory.

5. Manufacturing cost per unit is low.

Limitations

Following are the limitations of Mass Production:

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.

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