For better understanding of Production processes. better presentation all the production processes

1. PRODUCTION PROCESS
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 Work Center 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
Manufacturing 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.

22. THANK YOU
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