Manufacturing System

Introduction • Any manufacturing organisation can be termed as a production system to produce goods & services. There are three main components of this system namely inputs, transformation process and output. Combination of all activities and operations to produce some goods and services is known as manufacturing system.

Manufacturing systems • Production is the process by which goods and services are created. The inputs can be raw materials, components, paperwork, etc. whereas output are completed parts, products, paper work output services and scrap. The conversion process can be characterized as Receipt and storage of raw materials. These are drawn by the production department

• The manufacturing system may therefore be viewed as an interdependent groups of sub systems, each related to its successor, each performing a different function through yet united with other for achievement of overall system objectives. It interacts with both internal and external environment. The internal environment can be a combination of marketing, a/c’s, personnel and finance activities. The external environment can be combined effect

Types of Mfg Systems • Intermittent system • Continuous system

Intermittent System • These are those where the prod’n facilities are flexible enough to handle a wide variety of products and sizes. • Most products are produced in small qty’s. • Machines and equipments are laid out by process. • Workloads are generally unbalanced. • Highly skilled operators are reqd. for efficient use of machines and equipments. • In-process inventory is large.

• Planning and ctrl mechanism for intermittent systems is such that here the customers provides the blue print and other specification regarding the product to be mfg’d Then the org. Formulates their prod’n strategy to suit the needs of the customer

Types of Intermittent Systems • Job production : - Job or ‘make complete’ is the Production of single complete unit by one operator or group. Of operators e.g. bridge building, dam construction etc. Here whole project is considered as one operation and work is completed on each product before passing on to next. Each product is a class by itself and requires a distinct and separate job for prod’n purposes. The system requires versatile and highly skilled Labour wit high capital investment. Control of operations is

• In this system the goods are produced to definite customer’s orders. There is no assurance of continuous demand for specific items and the manufacturing depends on the receipt of orders from customers. 2. Whole project is taken as single operation. 3. Work is to be completed on each product before processing the next item. 4. Versatile and skilled Labour is needed . 5. High capital invt. 6. Control operations are relatively simple. 7. High unit cost of production. Any organisation manufacturing heavy and

Batch production • In the system of batch production any product is divided into parts or operations and that each operation is to be completed throughout the whole batch before the next operation is undertaken. The best example of batch prod’n system is of chemical industry, where different medicines are manufactured in batches. • In this system a batch is not passed to next operation until the work on the previous operation is complete for the whole batch and no new batch enters the prod’n line, till all the operations for mfg any product are completed. This results in considerable idle time for various

Features of Intermittent system 1. Demand can be discontinuous . 2. All operational stages may not be balanced. 3. Elaborate sequencing and scheduling is required. 4. Needs high invt. 5. Planning, routing and scheduling changes with fresh orders. 6. Storage is necessary at each stage of prod’n process. 7. Can adjust to new situation and specification.

Continuous system • In this the items are produced for the stocks and not for specific orders. Before planning mfg to stock, sales forecast is made to estimate likely demand of product and master schedule is prepared to adjust the sales forecast according to past orders and level of inventory. After setting master production schedule, detailed planning is carried on.

• In continuous manufacturing systems each production run manufactures in large lot sizes and the production process is carried on in a definite sequence of operations in a predetermined order. FIFO priority rules are followed in the system. In short, her input-output characteristics are standardized allowing for standardization of operations and their sequence.

Features of continuous system 1. 2. 3. 4. 5. 6. 7. 8.

There must be continuity of demand. The product must be standardized . Material shd. Be per specifications and delivered on time. All operations stages in the process must be balanced. Work must conform to quality standards. Appropriate plant and equipment must be provided. Maintenance must be by anticipation and not by default. Inspection must be in line with prod’n

Types of continuous system • Mass production • Process production

Mass production • Standardization is the fundamental characteristic of this system. Here items are produced in large quantity and much emphasis is given to consumers orders. In fact the is to stock and not to order. Uniform and uninterrupted flow of material is maintained through the predetermined sequence of operations reqd. to produce the product. The

Process prod’n • This method is used for manufacturing those items whose demand is continuous and high e.g. petroleum products, particular brand of medicines, heavy chemical industries etc. Here single raw material can be transformed into different kinds of product at different stages of the prod’n process e.g. in processing of crude oil in refinery one gets kerosene, gasoline etc. at different stages of production. • In mass and processing systems planning and scheduling for materials and finished products is done well in advance.