PRODUCTION SYSTEM
The combination of operations and activities, involving inputs, transformation process and output, employed to create goods and services is known as production system.
production system are also known as manufacturing system.
production system needs to interact with both internal (engineering, marketing, personnel & accounts activities) and external (customers, suppliers, competitors etc.) environment.
Classification Of Production System:
they are classified under two categories:
- Intermittent production system
- Continous production syste
(A) Intermittent (irregular) Production System
Intermittent means something that starts (initiates)& stops (halts) at irregular (unfixed) intervals (time gaps). In the intermittent production system, goods are produced on a small scale, based on the demands & orders of cutomers. The flow of production is intermittent and not continuous. this system is very flexible. Ex. (Ⅰ) The work of a goldsmith in hindi (sonar) is based on the customers orders. it is not continuous basis. (Ⅱ) The work of a tailor is also based on the number of orders he gets from his customers. The clothes are stitched (joint) on a limited scale for every customer independently as per their measurement & size & the joining is not done on a continuous basis.
Characteristics of an intermittent production system are:
- The flow of production is not continuous .
- Goods of varied designs & varieties are produced.
- The volume of production is small.
- The quantity, size, shape, design,etc. of the product depends on the customers requirements & orders.
TYPES OF INTERMITTENT PRODUCTION SYSTEM
1)JOBBING PRODUCTION SYSTEM:
- Jobbing production system are known as job shop production system
- This type of production system is concerned with making a high-priced product to order which is not likely to be repeated
Ex. tailoring shops,manufacturers of ships etc. Characteristics of jobbing production system are:
1)Low volume of production: The production made is by the strictly as per the customers orders
2)Discontinuous flow of material: The flow of material are not regularly
3)Large inventory of materials, Tools and parts
4)Highly skilled operators: The labour are highly skill developed that professional
5)Large work-in-progress (WIP):
Advantages of jobbing production:
- work is generally of a high quality.
- A high level of customization is possible to meet the customers exact requirements.
- workers can be easilu motivated and full potential can be utilized
Limitations of jobbing production:
- Higher cost due to frequent (common) set up changes.
- Production planning is complication.
- Requires the use of specialist labour.
- Larger space requirement.
(2) BATCH PRODUCTION SYSTEM
- In this types of production, a mixture of general purpose & special purpose equipment is used to produce small to large batch products.
- Batch production is one of the known as intermittent flow production.
- Ex. Ice cream manufactures produce a batch of ice creams of different flavour like vanilla and strawberry, heavy motor vehicles, process industries like pharmaceuticals, paints,etc.
Characteristics of batch production:
- short runs: Batch production has shorter poduction runs. the production is generally made to stock. the equipment & assembly set up is used for a limited number of parts or assemblies and is then changed to make a different product.
- Skilled labour: the labour force is expected to be skilled in any of processes link welding, fitting etc.
- Large WIP
- Proper production planning and control: Functions of production planning and control in batch production unit are more complex than those in jobbing production or mass production. ⠠ materials control and tools control function are important. ⠄There should be a proper stock control system to ensure routine replenishment. ⠄Often jobs tend to lag behind.
- General purpose machines: Batch production uses general purpose machines that are capable of performing variety of operations with minimum set-up time.
Advantages of Batch production:
➤ Better utilization of plant and machinery.
➤ Promotes functional specialization.
Limitations of batch production
➤ Production planning & control is complex
➤Material handling is complex
(B) Continuous production system
➤ Continuous means something that operates constantly regulated.
➤ In the continuous production system, goods are produced constantly as per demand forecast (अंदाजा) . Good are produced on a large scale for stocking & selling and not on customers orders.
➤ Example: The production system of a food industry is purely based on the demand forecast, where there is large-scale production of food and is continuous production.
characteristics of a continuous production system are:
- The flow of production is continuous.
- The production are standardized.
- The products are produced in anticipation (prevision-पहले से ही) of demand.
TYPES OF CONTINUOUS PRODUCTION SYSTEM
(A) Mass production system
- The mass production system is known as flow production system.
- Mass production system involve manufacturing of large number of similar product.
- Such products are stocked in warehouses till they are sold.
- It is the production of large amounts of standardized product.
- this production system is characterized by very large volume of production.
- Ex. refrigerators, television sets, electric fans etc.
Characteristics of mass production system
(a) continuous flow of material: In mass production system, the flow of materials, components & parts is continuous production.
(b) special purpose machines: there are dedicated special purpose machines that have higher production capacities and output rates.
(c) limited work-in-progress (WIP): since the manufacturing line is balance, the WIP is comparatively less.
(d) Short manufactring cycle time: The manufacturing cycle time is short as the machine capacities are balanced by duplicating wherever necessary.
(h) Material handling can be completely automatic.
Advantages of mass production system
➤ Higher rate of production with reduced cycle time
➤ Less skilled operators are required.
➤ Production planning & control is easy.
➤ Low process inventory.
➤ Manufacturing cost per unit is low
Limitation of mass production system
➤ Breakdown of one machine will stop an entire production line.
➤ High investment in production facilities.
(2) Process production system
- In process production there is manufacturing of a single product that is stocked in the warehouse for sales.
- The flexibility of such plants is almost zero as only one type of product can be produced in such plants.
Charateristics of process production system
(a) special purpose machine with Built-in controls: special purpose machinery and equipment with built-in controls to measure output & regular inputs are employed to suit the needs.
(b) Zero manufacturing cycle time: The one large machine where the raw materials enter at one end & energe as finished product at the other.
(c) Low skilled labour: Labour of process production include low skilled workmen.
(d) material handling: Material handling is highly machanixed using automatic transfer machines for movement.
(e) Small inventory of WIP: Negligible WIP as material flow is continuous.
Advantages of process production
➤ Higher, machanized material handling.
➤ Simple scheduling activity.
Limitations of process production system
➤ No flexibility ➤ Low skilled workmen.
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