By Anuradha Gaikwad

Production Process

An Activity whereby raw material is converted

into semi finished products and

thereby adds to the value of utility of products,

which can be measured as the difference

between the value of inputs and value of outputs.2

BIMAT

Production function Encompasses the activities of

procurement, allocation and utilization of resources.

The main objective of production function is to produce the goods and services demanded by the customers in the most efficient and economical way.

Therefore efficient management of the production function is of utmost importance in order to achieve this objective. 3

BIMAT

is a system whose function is to convert a set of inputs into a set of desired outputs.

LandBuilding

Goods Machines

and Labour capital

ServicesManagementMaterialOthers

Inputs Conversio

n Process

Outputs

Control

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BIMAT

1. Job Production System.

2. Batch or Intermittent Production.

3. Continuous Production.

4. Mass Production

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BIMAT

Herein one or few units of the products are

produced as per the requirement and

specification of the customer.

Production is to meet the delivery schedule

and costs are fixed prior to the contract.

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BIMAT

1. Space vehicles 2. Aircraft 3. Machine tools4. Special purpose

machines5. Tooling 6. Jigs 7. Fixtures

8. Custom clothing9. Prototype10. Large turbo

generators11. Material handling

machines12. Construction

equipment

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BIMAT

Irregular Small lots Flexible machines Skilled workers Very small quantities Specially made High variety low repetition Skills required are very broad

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BIMAT

Skilled jobber or team of jobbers complete the entire product

Fixed position or process layout Multi-skilled operatives One part of the task is completed before

next starts A project with a team which combines to

complete the whole is more complex Product routings vary widely

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BIMAT

Job is a unique product

Work is concentrated on a specific unit

supervision and inspection relatively simple

Specifications can change depending on the

customer demand

Operators become more skilled & competent

as each job gives them learning opportunity.10

BIMAT

Utilisation of full potential of operators.

Opportunity to use innovative ideas and

creative methods.

Working on a single unit, coping with a

variety of tasks gives more satisfaction.

General purpose machines help in variety

production.11

BIMAT

Under this system the goods are produced partly for inventory and partly for customer's orders.

E.g. components are made for inventory but they are combined differently for different customers.

Automobile plants, printing presses, electrical goods plant are examples of this type of manufacturing

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BIMAT

In this, limited quantities of each of the

different types of products are

manufactured on same set of machines.

Different products are produced

separately one after the other.

E.g., automobile parts, electrical goods,

etc. 13

BIMAT

1. Shorter production runs.2. Plant and machinery set up is is changed

as per requirements of the batch of items.3. More number of set ups and hence high

cost.4. Amount of supervision is less compared to

job order.5. Plant and machinery are flexible.6. Manufacturing lead time and cost are

lower as compared to job order production.7. Higher level of work in process inventory.

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BIMAT

1. Better utilisation of plant and machinery.2. Promotes functional specialisation.3. Cost per unit is lower as compared to job

order production.4. Lower investment in plant and macinery.5. Flexibility to accommodate and process

number of products.6. Job satisfaction exists for operators.

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BIMAT

1. Material handling is complex because of irregular and longer flows.

2. Production planning and control is complex.

3. Work in process inventory is higher compared to continuous production.

4. Longer production times.5. Higher set up costs due to frequent

changes in set up.6. Lower utilisation of production facilities

compared to mass production.16

BIMAT

It refers to the production of standardized products with a standard set of process and operation sequence in anticipation of demand.

It is also known as mass flow production or assembly line production.

Associated with continuous production and high demand.

The system is suitable for oil refineries, cement manufacturing etc.

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BIMAT

1. Steel

2. Ores

3. Cloth

4. Pharmacy products

5. gases.

6. Chemicals

7. Petroleum products

8. Cement

9. Rubber

10. Paint

11. Paper processing

BIMAT

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1. Dedicated plant and equipment with zero flexibility.

2. Material handling is fully automated.3. Wet or dry product flow measurable by

weight or volume.4. Shorter lead-times.5. Component materials cannot be

readily identified with final product and the product cannot be disassembled.

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BIMAT

6. The end product is not naturally divisible and hence n additional step such as bottling or canning is needed to get the product into saleable units.

7. Larger investment and usually capital intensive units.

8. Process follows a predetermined sequence of operations.

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BIMAT

9. Maintenance is an important aspect.

10. Unit coat is lower due to high volume.

11. Planning and scheduling is a routine

action.

12. Persons with (semi-skilled) limited skills,

can be used on production line.

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BIMAT

1. Variations in raw materials quality due to different sources of supply.

2. Processing technology variations.3. Variations in yields of output.4. Demand for by-products and joint

products.5. Shelf life of raw materials.6. Product differentiation is limited.7. Plant availability depends on preventive

maintenance system.22

BIMAT

Under this, the production run is conducted on a set of machines arranged according to the sequence of operations.

A huge quantity of same product is manufactured at a time and is stocked for sale.

Different products will require different manufacturing lines.

Since one line can produce only one type of product, this process is also called as line flow.

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BIMAT

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BIMAT

1. Standardisation of product & process sequence and hence product (line) layout is recommended.

2. Dedicated special purpose machines having higher production capabilities & output rates.

3. Large volume of products.4. Shorter cycle time of production.5. Lower in process inventory.6. Perfectly balanced production lines.

7. Flow of materials, components and parts

is continuous & without any backtracking.

8. Production planning and control is easy.

9. Extent of supervision required is less.

10. Material handling can be fully automated.

11. Unit per cost is low due to high volume.

BIMAT

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1. Higher rate of production with reduced cycle time.

2. Higher capacity utilisation due to line balancing.

3. Less skilled operator can man the process.

4. Low in process inventory.5. Production cost per unit will come down

due to economies of scale.

BIMAT

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1. Breakdown of one machine will stop an entire production line.

2. Line layout needs major adjustment / changes with the changes in the product design.

3. High investment in production facilities.4. Supervision is general rather than specific.5. Work for operators is monotonous without

much challenge.6. The cycle time is determined by slowest

operation.

BIMAT

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Under this, the production run is conducted for an run is conducted for an indefinite period.

Identical products are produced in large numbers.

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BIMAT

High volumes and low variety Standard repeat products Highly capital intensive and automated Few changeovers Difficult and expensive to start and stop Product layout usually along conveyors or

pipes No idle time Operators at work stations perform tasks as it

passes through the workstation Line is dedicated to one product only Flexible continuous flow line may be capable

of switching over to a model or product variant

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BIMAT

Ease of using just in time technique Labour and production costs reduced due

to detailed planning Deviants in the line are spotted through

quality control techniques No rest between operators so work-in-

progress levels can be kept low Space storage is minimum Physical handling is minimum Investment is quickly converted into sales Control is easy 30

BIMAT

Assembly line is industrial

arrangement of machines, equipment,

and workers for continuous flow of work

pieces in mass-production operations

First assembly line was introduced by

Henry Ford in 1908

Consists of sequence of work stations31

BIMAT

It is the issue of assigning tasks to the work

station

Tasks may require different times

Assignment of tasks times to work stations

are unequal

This leads to idle time 32

BIMAT

Assignment of tasks depends on demand rate

Depending on demand rate lines might be duplicated

Requires logical planning Distribute total job among the work

station so that all stations can complete their designed tasks at approximately same time

Split total assembly procedure into sub assemblies

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BIMAT

Demand is high duplicate entire line

Shortens the assembly line

May require more equipment and tooling

More tasks are assigned to a work station

Enriches work content

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BIMAT