PRODUCTION AUTOMATION (Lecture 6) TYPES OF PRODUCTION Two types of Production Modes can be adopted PTO PTS Products are

are made in advance and then stored as Inventory and shipped, as orders are received Production of items is based upon customers order Production to Order (PTO) Production to Stock (PTS)

PRODUCTION TO STOCK (PTS) Production Processes Kinds of Operations Kinds and Volumes of Resources (Raw Materials)

The above key parameters are known in advance, which results in easy Production Planning PRODUCTION TO ORDER (PTO) Exact Product specifications are established on the receipt of the customers order thus result in difficulty in the Production Planning

NOTE: Classification of Production is related to the Production Quantity or Volume of the Product per period of time (per month, per season or per year) Classification is (Job/Shop, Batch, Mass)

1. JOB SHOP PRODUCTION Main characteristic is very Low Volume Production Runs OF different Products Product Variation is High (Hard Product Variety) Products have very low level of STANDARDIZATION (common components/parts are very few or NIL) High Flexible production capability (To Produce different Products) Page 1

Dr. S.A. Shah

PRODUCTION AUTOMATION (Lecture 6) High Flexibility means (Flexible Equipment/Machines capable of performing different tasks) and Highly skilled work force (Labor) Specialized and Customized Products Customers Orders (Special and repeat orders may never occur)

POLICY

Operate a MTO or ETO Policy

2. BATCH PRODUCTION Definition Production of a product in small batches or lots by a series of operations, each operation being carried out on the whole batch before any subsequent operation is started on that batch

Characteristics POLICY Usually uses MTS poicy Can be MTO Main characteristic is Medium Volume Production Run OF Range of Products Production System (should be reasonably Flexible) General Purpose Equipment ( In order to accommodate fluctuations in Demand) Large Product Variety (Hence, has almost the same complexity of the Job-Shop)

3. MASS PRODUCTION Major Characteristic is Large Volume Production Runs OF relatively Few Products Products are highly standardized (level of STANDARDIZATION is High) Demand is stable for the product Stable Product Designs (Changes are very rare and little) Production Facilities consists of: o Dr. S.A. Shah Highly specialized and dedicated machines, and, Page 2

PRODUCTION AUTOMATION (Lecture 6) o o POLICY NOTE: HARD Automation of DETRIOT Automation is associated with Mass Production Hard in the sense that the Automation is dedicated and Inflexible Uses MTS Policy Associated Tooling Machines are expensive (However, cost is allocated over very long Production Runs)

Customer Delivery Time (LOW) Product Life Cycle (Long and Predictable) Customer Interaction (LOW)

MASS PRODUCTION has two categories 1. Quantity Production 2. Flow Line Production Quantity Production Involves mass production of single part on single piece of equipment Uses standard machines with special tools Example: (Stamping Machines with Dies)

Flow Line Production Involves multiple machines arranged in sequence Parts physically moves through that sequence to complete the product Work stations here are (Production machines with specialized Tools)

Dr. S.A. Shah

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PRODUCTION AUTOMATION (Lecture 6) PROCESS TYPES 1. JOB-SHOP Small Lots Low Volume General Equipment Skilled Workers High Variety Example: (Tool and Die Shop)

2. BATCH PROCESSING Moderate Volume and Variety Variety among Batches but not Inside Example: (Paint Production)

3. REPETITIVE/ASSEMBLY Semi continuous High Volume of standardized items Limited Variety Examples: (Auto Plants, Automotive Assembly, Auto Car Wash)

4. CONTINUOUS PROCESSING Very High Volume and No Variety Examples: (Steel Mill, Chemical Plant, Oil Refinery, Water Purification)

5. PROJECTS Non routine jobs Example: (Preparing Titanic)

Dr. S.A. Shah

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PRODUCTION AUTOMATION (Lecture 6) PRODUCT PROCESS MATRIX DIMENSION Job Variety Process Flexibility Unit Cost Volume of Output JOB-SHOP Very High Very High Very High Very Low BATCH Moderate Moderate Moderate Low REPETITIVE Low Low Low High CONTINUOUS Very Low Very Low Very Low Very High

VARIETY, FLEXIBILITY AND VOLUME MATRIX PRODUCT VARIETY EQUIPMENT FLEXIBILITY 1. LOW VOLUME 2. MODERATE VOLUME 3. HIGH VOLUME 4. VERY HIGH VOLUME High High Job shop Batch Repetitive Continuous Moderate Moderate Low Low Very low Very low

Dr. S.A. Shah

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