Group 3 ICE BREAKER

Project / one

Continuou s / many

Degree of repetitiveness

The conversion process has to be flexible with generalpurpose equipment, adaptive human skill and innovative procedures to suit the situation.

Characteristics
1. definite beginning & end 2. non-uniform requirement of resources 3. involvement of different agencies 4. fixed position layout 5. high cost over runs 6. personnel problems 7. scheduling & control

Job-shop system
This production system deals with manufacture of small lots of a large variety of products, which are customdesigned and built. Since each lot of products is unique, it manufacturing process and routing through different sections of the manufacturing facility will have general-purpose machines and varied human skills. Facilities are usually small and some equipment is overloaded.

Job-shop system
There are several patterns of flow speed is slow, run lengths are short and rate of change is rather slow. Owing to the variety of the jobs, routine is complex and control system is taxing, calling for quick responses, innovation and de-bottlenecking.

Examples: large turbo-generators, large

engines, boiler, processing, equipments, special electronic equipment, shipbuilding etc.

Characteristics
1. Small production runs 2. discontinuous flow of materials 3. disproportionate manufacturing cycle time 4. general purpose machines & process layout 5. highly skilled labor 6. highly competent knowledgeable supervision 7. large WIP 8. limited functions of PPC

Batch system
This is the manufacture of a number of identical articles, either to meet customer demand or to satisfy continuous demand. When the lot size is larger than job shop, the facilities are also of moderate scale. Several jobs are repeated in large volume. There are some dominant products but their quantities are not so large as to warrant-dedicated machines. Batch production system is geared to make a large variety of products in varying volume with the help of general-purpose machines and varied human skills.

Characteristics
1. Short runs 2. Skilled labor in specific trades 3. Supervisor to possess knowledge of specific process 4. Limited span of control 5. General purpose machines & process type layout 6. Manufacturing cycle time affected due to queues 7. Large WIP 8. Flexibility of production schedules 9. Need to have PPC

Continuous
The specialized manufacture of identical articles on which the equipment is fully engaged. It is normally associated with large quantities and with a high rate of demand. There are two types of continuous production: Mass production and Flow production. Plant size has a very wide distribution, but most of the plants are of small or medium size.

Assembly-line system
When the product range is small and volumes are large, assembly line production system is employed with specialized equipment, specific manufacturing procedures and human skills and management systems. Speed is high, run lengths are reasonably long . There is a great deal of emphasis on productivity improvements involving assembly line balancing, staffing in the event of absenteeism etc.

Characteristics Of Assembly Lines

1. Continuous flow of material 2. Special purpose machines 3. Product layout 4. Mechanized materials handling 5. Low skilled labor 6. Short manufacturing cycle time 7. Easy supervision 8. Limited WIP 9. Lesser flexibility in production schedules 10.Some of assembly line products are : TV ,Fridge, Washing Machines ,Motor Cars

Continuous Process Flow System

Process production is characterized by manufacture of a single product and stocked in warehouse awaiting sales. Chemical plants, fertilizer manufacturing units and oil refineries use continuous-flow p0roduction systems. Raw materials are processed through different stages in a continuous flow in obtaining finished products, which are packed as required. sugar , cement ,paper , milk ,coke etc

Characteristics Of Process Plants

1. Special purpose machines with built in controls 2. highly mechanized material handling 3. virtually zero manufacturing cycle time 4. low skilled labour 5. supervisor to be process specialist 6. negligible WIP 7. limited production planning & control functions

Selection of manufacturing process

In reality , very few organizations use only one process type in true sense. Generally , at least 2 or 3 process Manufacturers of automobile , electric appliances , copiers etc use batch production to manufacture components & some subassemblies and flow production for final assembly Manufacturing process like a product has a life cycle . Product starts with project form Then small batches in growing stage Then in maturity phase mass & flow

project

batch
Mass & flow

continuous

Introduction ( use project form ) Growth ( use batch form )

Maturity( use mass form )

Maturity ( use process form )