Production System

1. PRODUCTION SYSTEM
Ankush Singla
Assistant Professor
TIMT

2. PRODUCTION
Production can be explained as an act of either manufacturing or mining or growing of
goods (commodities) generally in bulk for trade. Production is a method employed for
making or providing essential goods and services for consumers.
It is a process that puts intangible inputs like ideas, creativity, research, knowledge,
wisdom, etc. in use or action. It is a way that transforms (convert) tangible inputs like
raw-materials, semi-finished goods and unassembled goods into finished goods or
commodities.

3. SYSTEM
System is an arrangement or assembly of inter-dependent processes (activities)
that are based on some logic and function. It operates as a whole and is
designed (build) with an intention to achieve (fulfill) some objective or do some
work. Huge systems are often a collection (assembly) of smaller sub-systems.

4. PRODUCTION SYSTEM
"The methods, procedure or arrangement which includes all
functions required to accumulate (gather) the inputs, process or
reprocess the inputs, and deliver the marketable output (goods)."
Production system utilizes materials, funds, infrastructure,
and labour to produce the required output in form of goods.

5. Inputs include raw-materials, machines, man-hours, components or parts,
drawing, instructions and other paper works.
Conversion process includes operations (actual production process).
Operations may be either manual or mechanical or chemical. Operations
convert inputs into output. Conversion process also includes supporting
activities, which help the process of conversion. The supporting activities
include; production planning and control, purchase of raw-materials, receipt,
storage and issue of materials, inspection of parts and work-in-progress,
of products, quality control, warehousing of finished products, etc.
Output includes finished products, finished goods (parts), and services.

6. Concept Definition
Production System A system whose function is to convert a set of inputs into a set of desired
outputs.
Conversion Sub- A sub-system of the larger production system where inputs are converted into
outputs.
Control Sub-system A sub-system of the larger production system where a portion of the output is
monitored for feedback signals to provide corrective action if required.
Production system
receives inputs in the
form of materials,
personnel, capital and
information.
These inputs are
changed in a
conversion sub-system
into desired products
and services which are
called the outputs.
A portion of the output
is maintained in the
control sub-system to
determine if it is
acceptable in terms of
quantity, cost and
quality.
If the output is
acceptable, no
are required in the
system.
If, however, the
appropriate standards
are not met,
corrective action is
required.
The control sub-system
ensures a uniform level
of system performance
by providing feedback
information so that
corrective action may
be taken by managers.
PRODUCTION SYSTEM CONCEPTS

7. Environment
Legal/Political
Social, Economic,
Technological
Market
Competition
Product Information
Customer Desires
Primary Resources
Materials & Supplies
Personnel
Capital
Physical
(Manufacturing, Mining)
Locational Services
(Transportation)
Exchange Services
(Retailing/ wholesaling)
Storage Service
(Warehousing)
Other Private Services
(Insurance, Finance, Health,
Business Service, Personal Service)
Government Service
(Local, State, Central)
Goods or Services
Feedback
Informatio
n
Inputs Conversion Sub-system Outputs
Control Sub-system

8. EXAMPLE
Refined
Sugar
Sugarcane
Juice
Sugarcane
Executable
Application
Program
Integrated with
User Friendly
Interface
Written
Program Codes
Tangible
Goods
Intangibl
e Goods

9. TYPES OF PRODUCTION SYSTEM
Intermittent
Production System Continuous/ Flow
Production System

10. Production
System
Intermittent
Production
Project Job Batch
Flow/ Continuous
Production
Mass Process Assembly Lines

11. INTERMITTENT PRODUCTION SYSTEM
Intermittent means something that starts (initiates) and stops (halts) at irregular (unfixed) intervals. Intermittent
production refers to the process where production is not uniform and the product changes from time to time. There is
thus, No single procedure and the facilities are flexible enough to meet the requirements of change.
In the intermittent production system, Goods are produced based on customer's orders. These goods are produced on
a small scale.
In this system, large varieties of products are produced. These products are of different sizes. The design of these
products goes on changing as per the need and want of the customer. Therefore, this system is very flexible.

12. INTERMITTENT PRODUCTION SYSTEM
(EXAMPLE)

13. INTERMITTENT PRODUCTION SYSTEM
(EXAMPLE)
The work of a goldsmith is purely based on the frequency of his customer's orders. The goldsmith
makes goods (ornaments) on a small-scale basis as per his customer's requirements.
Similarly, the work of a tailor is also based on the number of orders he gets from his customers.
The clothes are stitched for every customer independently by the tailor as per one's measurement
and size. Goods (stitched clothes) are made on a limited scale and is proportional to the number of
orders received from customers.

14. INTERMITTENT PRODUCTION SYSTEM
(FEATURES)
The flow of production is not continuous. It is intermittent.
Wide varieties of products are produced.
The volume of production is small.
General purpose machines are used. These machines can be
used to produce different types of products.
The sequence of operation goes on changing as per the
design of the product.
The quantity, size, shape, design, etc. of the product
depends on the customer's orders.

15. FLOW/CONTINUOUS PRODUCTION
SYSTEM
Continuous means something that operates constantly without any irregularities or frequent halts.
Continuous production refers to the process where production is uniform. Goods are produced constantly as per demand forecast.
Goods are produced on a large scale for stocking and selling.
In the Continuous production system, Goods are not produced based on customer's orders. These goods are produced on a large scale.
In this system, the inputs and outputs are standardized along with the production process and sequence.

16. CONTINUOUS PRODUCTION SYSTEM
(EXAMPLE)

17. CONTINUOUS PRODUCTION SYSTEM
(EXAMPLE)
The production system of a food industry is purely based on the demand forecast. Here, a
large-scale production of food takes place.
Similarly, the production and processing system of a fuel industry is also purely based on,
demand forecast. Crude oil and other raw sources are processed continuously on a large
scale to yield usable form of fuel and compensate global energy demand.

18. CONTINUOUS PRODUCTION SYSTEM
(FEATURES)
The flow of production is continuous. It is not intermittent.
The products are standardized.
The products are produced on predetermined quality
standards.
The products are produced in anticipation of demand.
Standardized routing sheets and schedules are prepared.
The volume of production is large.

19. S. No. Characteristics Intermittent Production System Continuous Production System
1 Volume of Production Limited Large Quantity
2 Product Variety Wide Range of products One or few Standard products
3 Layout Process or Functional Product Layout
4 Manufacturing Cycle Time Medium to Large Low
5 Material Flow Discontinuous Continuous and Uninterrupted
6 Flexibility High Low
7 Equipment and Machinery General Purpose Specific Purpose
8 Cost per Unit Medium to High Low
9 Investment Low to Medium High
10 Material Handling Manual or Semi Automatic Automated
11 Labour Highly Skilled Semi Skilled or Unskilled
12 Production Planning and
Control
Complex due to non-repetitive
nature of order
Simple or routine

20. PROJECTS
Project may be defined as a plan for an undertaking involving huge cost and time. It is one
time major task that must be completed within a certain period of time and at an estimated
cost.
Project technology deals with products that are tailored to unique customer requirements. The
products are not standardised and so the process is flexible.
The resources are brought to the location where the product is to be fabricated. Once the
project is completed, the resources of the projects are redirected to a new project.
Various techniques such as bar charts, network analysis, PERT, CPM etc. help in completing the
project on schedule with the desired cost frame.
Example: Construction of Roads, Dams, Airports, Shipbuilding etc.

21. PROJECTS (FEATURES)
Project is one time task, which may not repeat in exactly the
same manner.
Project has to be completed in a time bound schedule.
Once the project is completed, resources are deployed to
new project.
The resources and skills are of diversified nature.
The requirement of resources is not same (it varies).
Generally, the resource requirement at the beginning is low.
Then in mid of production, the requirement increases.
Finally, it slows down when the project is near its completion
phase.Project may be small, medium and large, depending upon the
number of tasks involved.

22. PROJECTS (DISADVANTAGE)
Many agencies are involved
in the project. Each agency
performs specialized jobs.
There may be a problem of
coordination between them.
The Project specialist may
feel insecure regarding their
future prospects once the
project is completed.
The project normally take
long time to finish and there
may be absence of
motivation among the
specialists.
Delay takes place in
completion of project due
to its complexity and
massiveness.

23. JOB PRODUCTION
Under this method, special or non-standardized products are produced in accordance with the
orders received from the customers.
As each product is non- standardized varying in size and nature, it requires separate job for
production. The machines and equipment’s are adjusted in such a manner so as to suit the
requirements of a particular job.
Job production involves intermittent process as the work is carried as and when the order is
received. It consists of bringing together of material, parts and components in order to
assemble and commission a single piece of equipment or product.
Example: Boilers, Machinery, Tailoring

24. JOB PRODUCTION (FEATURES)
A wide range of general purpose machines are required.
A wide range of workers conversant with different jobs will
have to be employed.
A large inventory of materials, parts, tools and items are be
required.
The setting of machines and equipment will have to be
adjusted and readjusted to the manufacturing needs.
The movement of materials through the process is
intermittent.

25. JOB PRODUCTION (DISADVANTAGE)
The economies of
large scale production
may not be attained
because production is
done in short runs.
There is irregularity in
demand for some
products.
There may be an
insufficient use of
labour and
equipment.
Requires investment
in skills and training

26. BATCH PRODUCTION
Batch Production pertains to repetitive production. It refers to the production of goods, the
quantity of which is known in advance.
It is that form of production where identical products are produced in batches on the basis of
demand of customers’ or of expected demand for products.
This method is generally similar to job production except the quantity of production. Instead of
making one single product as in case of job production, a batch or group of products are
produced at one time.Under batch system of production the work is divided into operations and one operation is
done at a time. After completing the work on one operation it is passed on to the second
operation and so on till the product is completed.
Example: Biscuit and confectionery, Medicines

27. BATCH PRODUCTION (FEATURES)
The work is of repetitive nature.
There is a functional layout of various manufacturing
processes.
One operation is carried out on whole batch and then is
passed on to the next operation and so on.
Same type of machines is arranged at one place.
It is generally chosen where trade is seasonal or there is a
need to produce great variety of goods.

28. BATCH PRODUCTION (DISADVANTAGE)
It becomes
difficult to
decide a proper
batch lot.
Material
handling is
longer.
Production
time is
generally
longer.
Decision about
the sequence of
batches is also
a problem.

29. MASS PRODUCTION
This production refers to the manufacturing of standardized parts or components on a large
scale.
Mass production system offers economies of scale as the volume of output is large.
Quality of products tends to be uniform and high due to standardization and mechanization.
Electronics, electrical, automobiles, bicycles and container industries are a few examples of
mass production industries.

30. MASS PRODUCTION (FEATURES)
There is standardization of product and process sequence.
Large volume of products.
Flow of materials, components and parts is continuous.
Material handling is fully automated.
Cost per unit is low, due to high volume of production.

31. MASS PRODUCTION
Advantage Disadvantage
Low cost per unit due to economies of scale. Break down of one machine stops the entire
production line.
Higher rate of production with reduced cycle time. High investment in production facilities.
Higher capacity utilisation due to line balancing Work is monotonous without much challenge.
Almost fully automated, less skilled operators
required.
Less flexibility

32. PROCESS PRODUCTION
This system is an extended form of mass production where production is carried on
continuously through a uniform predetermined sequence of operations.
Generally under this system finished product of one process is used in the next process as a
raw material until the last process.
Process production can further be of two types-
Analytical Process – Where the raw material is transformed into several products at different
stages of operations. For Example- Crude oil is processed into kerosene, gasoline, and other
products.
Synthetic Process – Where two or more materials are combined to manufacture a product.Example: Large industries like petroleum refining, heavy chemical industries generally use this
system of production

33. PROCESS PRODUCTION (FEATURES)
Dedicated plant and equipment is required.
There is a highly mechanized system for handling materials.
Conveyors and automatic transfer machines are used to move
the materials from one stage to another.
Large investment.
Demand for – By products and joint products.
There is very less work-in-progress because material flow is
continuous.
The production planning and scheduling can be decided well
in advance.

34. PROCESS PRODUCTION
Advantage Disadvantage
Process can normally be automated which reduces
unit cost.
Heavy investment required.
Large quantities can be produced. Difficult or disruptive if the production process has
to be stopped.
Ideal for products which have to be of a consistent
quality.
Little opportunity to make different versions of the
product.

35. ASSEMBLY LINES
In assembling process, two or more components are combined to manufacture a finished
product. Manufactured parts are joined into sub-assemblies or final assemblies.
Assembly line is a type of flow production which was developed in the automobile industry in
the U.S.A.
A manufacturing unit prefers to develop and employ the assembly line because it helps to
improve the efficiency of production. The use of flow production methods results in cost
reduction.
Assembly line is particularly useful when a limited variety of similar products is to be produced
on a mass scale or in fairly large batches on a regular or continuous basis.
Such process is employed in assembling automobiles, radio sets, television sets, bicycles,
watches, cameras, etc.

36. ASSEMBLY LINES
In an assembly line, each machine must directly receive material from the previous machine
and pass it on directly to the next machine. Therefore, the location of machines is
automatically regulated by the sequence of operations.
Machines and equipment should be arranged in such a manner that every operator has a free
and safe access to each machine.
Space should be provided for free movement of fork lifts, trucks, etc., which deliver materials
and collect the finished products. The passage should not be blocked and workers must not
be in danger of being hit by the moving trollies, etc.

37. ASSEMBLY LINES
Highly specialized machines and workers
Low unit costs
Consistent quality
Not much flexible

38. REFERENCES
 1) K Aswathappa and K Shridhara Bhat, Production and Operation Management,
Himalaya Publication House
 2) Gupta Neeti, Gupta Anuj and Bansal Manoj, Principles of Production
Management, Kalyani Publication House