batch process presentation]

8/6/2019 Batch Process Presentation]

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BATCH PROCESS

Jens Thomas


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Aim and Objective

Aim :To explain about the batch production system followed in

Manufacturing industry.

Objective :

To understand the characteristics of batch production

To know about the implementation of batch production

in industries

To understand the advantages and disadvantages of

batch production.


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Term batch refers to a definite group of components,

which go through a production process together. As

one batch finishes, the next one starts.

Production of different type of engine parts can be

taken as an example.

Batches are continually processed through each

machine before moving into the next operation.

Introduction


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In other words, the batch flow production system produces

low volumes of many different products for one of the

three reasons

-Customers place one time orders for small

quantities.

-Customers prefer to place small repeat orders from

time to time.

-The organisation prefer to accumulate orders from

different customers for the same or similar products

into a batch and produce them together.

Introduction Contd.


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Functional and cellular layouts are used in the batch

flow production system[3].

Flow of material in functional layout is irregular and

considerable material handling is needed for moving

the batches from department to department.

In the case of cellular layout, the material flow is less

varied.

Layout and material flow


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Batch process layout[2]


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Short Runs

The equipments and assembly setup are used for a

limited number of assemblies or parts and are then

changes to make a different product[4].

Skilled labor in specific trades

The labors are expected to possess skill in their

related specific manufacturing process.

Supervisor to possess knowledge of a specific

process

The supervisors should have considerable knowledge

of each specific process.

Characteristics of batch process


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Limited span of control

The amount of supervision required in batch production

is lower. The ratio of direct workmen to supervisors

changes depends on the batch size.

General-purpose machines and process type of layout

Plant and equipments are procured and arranged to

obtain maximum flexibility.

Less Manual materials handling

Materials handling in batch production is minimum.

Characteristics contd.


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Manufacturing cycle time affected due to queues.

The batches of work tends to queue up at different

machines due to batch sizes, differing cycle times etc.

Large work-in-progress.

WIP is large due to varying work content of different

components, and formation of queues b/n machines.

Flexibility of production schedules.

Disruptions due to absenteeism or machine breakdowns

do not seriously affect production as job can be shifted to

another operator or another machine.

Characteristics contd.


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CJC is a Denmark based manufacturing firm

producing plow, seed drills, spreaders etc.

Plant fabricates 6000 different parts.

Almost all the parts were required in low volume.

Low volumes of different parts required resulted in

frequent changeovers.

Frequent changeovers contributed to frequent machine

down time.

To compensate this, products were manufactured in small

batches.

Case Study CJC [5]


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Key findings

When a machine takes long conversion time , it

saves time to just run a whole bunch of pieces once

the settings are completed.

By using batch production fewer defects are there.

Better levels of cost and quality were the prime

results.

Better utilisation of machines.

Case Study contd.


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Advantages It is cheaper to produce a whole batch instead of single line

production.

This system is not very capital intensive. Less investment

is required in machines

A single production line can be used to produce

several products.

Machines can be used more efficiently.

Advantages and disadvantages[6]


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The number of machines required is lesser because they

are utilized for multiple lines of the same product

Specialized supervision is possible in such a system

It provides for greater flexibility with respect to labour and

equipment

Advantages and disadvantages


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Disadvantages Batch production requires very careful planning to decide

what batch will be produced and when.

Batch production can result in the build up of significant

work in progress.

Work in progress requires large workspace and capital.

More skilled workers are required to produce different

lines of the same product

Advantages and disadvantages


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References

[1] unknown, http://www.thetimes100.co.uk/theory/theory--production-process--254.php, Retrieved on16thjanuary2010

[2] unknown http://www.mbaknol.com/operations-

management/batch-production-and-its-key-

characteristics,Retrieved on16thjanuary2010

[3] John Miltenburg, Manufacturing Strategy, Productivity press,1995


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References

[4] unknown http://www.technologystudent.com/joints/bat1.htm,

Retrieved on16thjanuary2010

[5] unknown http://tutor2u.net/business/gcse/production_batch.htm,

Retrieved on 16 thjanuary2010

[6]Unknown,http:// http://www.tutorsonnet.com/operations_managem

ent_homework_help/production_planning/planning_and_control_of_b

atch_production_assignment_help_tutoring.htm, , Retrieved on16th

january2010


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batch process presentation]

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