The document discusses different types of production processes. There are four main types: job shop production, batch production, mass production, and continuous/flow production. Job shop production involves unique custom products in low volumes. Batch production groups similar products into batches. Mass production focuses on high volumes of standardized products. Continuous production involves a linear and automated process with no backtracking.

1. Types of Production Processes
What is a Production System?
• Production System are those activities of an
organization where
Types of Production Processes – resources flowing within a defined system
– are combined and transformed
Presented By: – in a controlled manner
Anupam Kumar – to add value
Reader – in accordance to the policies communicated by
SMS Varanasi the management.
Characteristics of a Production System Types of Production Systems
• Production is an organized activity, so every • The types of production processes / systems are
production system has an objective. classified on the basis of
• The system transforms various inputs to useful – Product / Output Variety and
outputs. – Product / Operations / Output Volume
• It does not operate in isolation from other • They are broadly classified as:
organizational systems. – Continuous Production Process
• Process / Flow Production
• There exists a feedback about the activities, • Mass Production
which is essential to control and improve – Intermittent Production Process
system performance. • Batch Production
• Job Shop Production
Types of Production Processes Types of Production Process
• Production processes or manufacturing • There is yet another type of production process
operations may broadly be divided into two • The third type of production process is one where
categories. – The company produces standard modules and
– Made to stock production process – assembles these modules
• These firms make items that are completed and placed in – according to the specifications of a customer order
stock before customer order is received.
• This type of production process is Assemble-to-Order
– Made to order production process production process. E.g.
• These complete the end item only after receiving a customer
order. – PVC window assemblers,
• This is because manufacturer cannot anticipate what each – modular kitchen board assemblers, etc.
customer wants.
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2. Types of Production Processes
Types of Production Processes Types of Production Processes
• Another way to define the type of production Project
process is based on the extent to which a factory has Job-shop
Production
the flexibility to produce a variety of products. Process
• This can be categorized as follows Intermitted Batch
– Continuous Production System Production Production
Variety Continuous
System Process
• Flow Production System Production
• Mass Production System Mass System
Production
– Intermitted Production System Process
• Batch Production System
• Job-shop Production System Flow Production
• Project Production System Process
Volume
Continuous Manufacturing System Repetitive Manufacturing
• These are also referred to as Repetitive
Manufacturing Systems. • WIP is low because the items move
• These are mass production facilities that quickly in the plant.
produce high volumes of the same products. • Examples are television, radio, and
• They are usually make-to-stock producers. telephone producers.
• The manufacturing happens in Automated, • Product(s) follow the same path:
special-purpose equipments.
Continuous flow (flow shop) Continuous flow (flow shop)
• Continuous flow operations are sometimes
• Some products flow also called process type operations
continuously through – (as opposed to discrete operations).
a linear process. • Examples are
• These types of – Chemical plant,
operations are called
– Oil and Gas,
continuous flow (flow
shop) operations. – Petroleum refineries,
• Usually the products – Sugar mills, etc.
are not discrete.
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3. Types of Production Processes
Process Production / Flow Production Mass Production Process
• When is it used: • When is it used: • Advantage:
• Advantages:
– Dedicated plant and – Standardization of product – Higher rate of production
– Standardization of product with reduced cycle time.
equipment with zero and process sequence and process sequence
flexibility – Dedicated special purpose – Higher capacity utilization
– Higher rate of production due to line balancing
– Material handling is fully with reduced cycle time. machines having high
automated. production capacities and – Less skilled operators are
– Highest capacity utilization output rates required.
– Process follows a due to line balancing
predetermined sequence of – Large volume of products – Low process inventory
operations – Manpower is not required for
material handling. – Shorter cycle time – Manufacturing cost per unit is
– Component material cannot – Lower in process inventory low.
be readily identified with final – Persons with limited skills can
product be used for production – Balanced production lines • Limitations
process. – Material and parts flow is – Break-down of one machine
– Planning and scheduling is a continuous without back- may stop entire production
routine action – Unit cost is low due to high
volume of production . tracking line.
– Product differentiation is – Production planning and – Line layout needs major
limited. control is easy changes with changes in
– Involves high initial – Material handling can be product design.
investments. completely automatic – Higher investment in
production facilities.
Intermitted Production Process Job Shop Production Process
• In this type of production process
– The volume of each product is low. Job 1
Job 2
– Generally produces make-to-order, custom products
in accordance with design supplied by the customer.
– Each job may be unique and may require a special set
of production steps.
– Further, each job may require a particular routing. Job 4
Job 3
– There are no standard routings.
– Products may follow different paths.
– Needs general-purpose production equipment
Job Shop Production Process Job Shop Production Process
• Job shop production process are used in • When is it used: • Advantages:
– High variety of products with – A large variety of products
– woodworking shops, low volume can be produced with the
– Use of general purpose general purpose machines
– metal fabrication shops, etc. machines and facilities – Operators become more
– Highly Skilled Operators who skilled and competent with
• May require an inventory of a few type of the take up each job as a each job
raw materials. challenge – Full potential of operators can
– Large inventory of materials, be utilized
• BUT, here the largest percentage of the tools and parts – Opportunity exists for
– Detailed planning is essential creative methods and
inventory is Work in Process (WIP). for sequencing of each innovative ideas.
product Capacities for each • Limitations:
• Work in Process is the inventory that work centers and order
priority – Production planning is
accumulates in between process stages. complicated
– Larger space requirement.
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4. Types of Production Processes
Batch Manufacturing Batch Manufacturing
• Many manufacturing operations fall between • The batch manufacturing company makes a
job shops and repetitive manufacturing. batch of one product, then may switch over
These are called batch manufacturing. (set up) the equipment and make a batch of
– Batch means a single production run another item.
– Batch size means the quantity produced in a single
production run. • Production equipment should be more flexible
– It may be less than 100 units OR up to a few 1000 than repetitive manufacturing and it is
units. generally less flexible than job shops.
Batch Manufacturing Batch Production Process
• When is it used: • Advantages:
– There is a shorter production – Lower manufacturing lead
• Here, products having run time and cost as compared to
– Plant and machinery are job order production process.
same or similar flexible – Better utilization of plant and
processes may be – Every batch of production machinery
requires changes in the plant – Promotes functional
grouped into a and machinery set-up. specialization
product family. • Limitations: – Lower investment in plant
– Material handling is complex and machinery
• Examples are small – Production planning & control – Flexibility to accommodate
is complex and process number of
hand tools (e.g., drill, products
– High set-up cost due to – Job Satisfaction to operators.
screw driver), and frequent changes in set ups.
hand mixers. – WIP inventory is higher than
continuous production
process.
Project type Project type
• A project is a highly flexible and low volume type • Some types of service operations may also be
operation.
called as Projects.
• Usually the item to be produced stays in a fixed place
and all the resources come to it. • These involve a team of people over a period
• At the end of production, resources leave the place. of time and then the people leave the project.
• Examples are • Example:
– ship construction,
– Developing a software package may be a project
– bridge construction,
type of service operation.
– buildings and
– large machines.
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5. Types of Production Processes
Basis for Comparison of
Types of Production Process
Production Processes
• Job Shop Production Process • Manufacturing Cost • Flexibility of Production
– These are characterized by manufacturing of one or few quantity of
products designed and produced as per the specification of the • Capital Investment • Types of Products
customer within prefixed time and cost
• Batch Production Process – Plant Produced
– It is a form of manufacturing in which the job passes through the – Inventory • Material Handling
functional departments in lots or batches and each lot may have a
different routing. • Size of Plant Equipment usage
• Mass Production Process
– Manufacture of “discrete parts” or assemblies using a continuous • Technical Requirements • Security of Job
process is called mass production. – To workers
• Flow / Process Production System
• Organizational Structure
– The production process in which the items are made to flow through – To employees.
the sequence of operations by various devices right from the first
operation to the finished product stage is called a flow or process
production system.
To Objectives of Operations
Management …
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