Production Systems and Characteristics

Different Forms of Production Systems

• Production by Extraction or Separation: Involves processes that extract resources from nature, e.g., petrol, kerosene, and sugar.
• Production by Assembly: Focuses on assembling various components into a final product, e.g., cars, televisions, and furniture.

Characteristics of Continuous/Mass Production

• Manufacturing the same product over extended periods allows for a systematic machine arrangement.
• Utilizes standardized methods and machines throughout part manufacturing.
• Mostly uses semi-automatic or fully automatic equipment to enhance efficiency.
• Automated material handling systems, such as conveyors, streamline production.
• Semi-skilled workers fill positions since automation reduces the need for extensive manual labor.
• Easier planning and control are possible due to the product's predefined flow along production lines.
• Unit production costs are low due to high production rates and efficiency.
• Low in-process inventories result from simplified scheduling and implementation.

Characteristics of Job or Unit Production

• Machines and methods are general-purpose, accommodating frequent product changes.
• Skilled manpower is essential for adapting to varying work conditions.
• Lack of firm schedules due to unpredictable production data.
• Typically high in-process inventory, influenced by the absence of accurate planning.
• Product costs are elevated from high material and labor expenditures.
• Machines are grouped functionally, enhancing flexibility to produce different product types.
• Material handling systems must adapt to meet changing product requirements.

Characteristics of Intermittent/Batch Production

• Products manufactured in batches allow for some economies of scale.
• Machines grouped based on functionality, similar to job shop practices.
• Utilizes semi-automatic and special-purpose machines for standard products.
• Skilled labor is required to manage diverse product batches.
• High in-process inventory is common due to specific layout and handling policies.
• Semi-automatic material handling systems align well with semi-automatic machinery.

Process Planning

• Defined as the process of determining the necessary operations and sequences to create a product.
• Involves selecting, specifying processes, machine tools, and equipment to transform raw materials into finished products per design specifications.
• Purpose:
  • Establish clear requirements to facilitate machine and tool design or purchase.
  • Ensure coordination among all manufacturing personnel.
  • Develop a plan for optimal use of available resources and facilities.

Steps in Process Planning

• Analyze the finished product to identify sub-assemblies and components for manufacturing.
• Prepare a Bill of Materials (BOM) to serve as a foundation for raw material purchases.
• Determine which components to manufacture in-house versus which to procure externally, making a "make or buy" decision.
• Select an appropriate size of raw materials (blank size) and evaluate the most cost-effective methods for component production, comparing potential processes to finalize choices.

Explore the various forms of production systems, including extraction and assembly processes. Learn about the characteristics of continuous and mass production, focusing on efficiency and automation in manufacturing environments.