The production system is the component of an organization that produces its products. It is the process of integrating and changing resources moving through a defined system under strict control to add value in accordance with management-communicated policies. The diagram above depicts a simplified production system.
The following characteristics characterize the production system:
- Because production is a planned activity, every production system has a goal.
- The system converts the different inputs into useful outputs.
- It does not operate independently of the other organizational system.
- There is feedback on the activities, which is necessary for controlling and improving system performance.
Job Shop, Batch, Mass, and Continuous Production systems are the four types of production systems.
Job Shop Production
Job shop production is defined as the production of one or a small number of products in a set amount of time and money while adhering to the customer’s specifications. The small volume and wide range of products set this apart.
A job shop is divided into several sections for general-purpose machines. Every job has unique technological requirements that must be met by machines in a specific order.
Characteristics
The Job-shop production system is followed when there are:
- Low volume and a wide range of products.
- General-purpose machines and facilities are used.
- Because of their uniqueness, highly skilled operators can view each job as a challenge.
- Material, tool, and part inventory is extensive.
- For sequencing the requirements of each product, capacities for each work center, and order priorities, detailed planning is required.
Here are some examples of job shop production:
- Custom Furniture Manufacturing: A furniture workshop that creates custom furniture based on the customer’s specifications. For each component, different materials, patterns, and finishes may be required.
- Print Shops: Printing firms that specialize in personalized products such as invitations, brochures, and business cards. Each order may differ in terms of design, type, and quantity.
- Machine Shops: Facilities that manufacture specialized machined components for diverse industries. These components are frequently produced using specialist equipment to exacting standards.
- Prototyping Services: Organizations that provide services for product development prototyping. To test and improve designs before to mass manufacturing, they make small batches of prototypes.
- Custom Jewelry Production: Jewelry designers who design distinctive pieces of jewelry based on client preferences. Different gemstones, metals, and designs could be used in each piece.
- Tailoring and Clothing Alterations: Tailoring businesses that offer modifications and custom tailoring for clothing. Every garment customization or alteration is particular to the needs of the customer.
- Aerospace Component Manufacturing: Establishments that make specialist parts for the aerospace sector. There are tight quality and performance requirements for every component.
- Specialty Bakeries: Bakeries that make specialty delicacies, pastries, and cakes for special occasions like birthdays and weddings. Specific tastes, designs, and decorations may be included in each order.
Batch Production
Batch production is described as “a form of manufacturing in which the job passes through the functional departments in lots or batches and each lot may have a different routing” by the American Production and Inventory Control Society (APICS). It is distinguished by the production of a small number of items that are manufactured at regular intervals and kept on hand for sales.
Characteristics
The batch production system is used in the following situations:
- When there are shorter production runs.
- When plant and machinery are flexible.
- When plant and machinery set up is used for the production of the item in a batch and a change of set up is required for processing the next batch.
- When compared to job order production, the lead time and cost of manufacturing are lower.
Examples of Batch Production
- Soap.
- Food products such as meals, baked goods, etc.
- Clothing in different sizes and designs.
- Sporting goods.
- Electrical goods.
- Newspapers, magazines, and books.
- Computer chips
Mass Production
Mass manufacturing is the continuous process used to produce discrete parts or assemblies. The extremely high manufacturing volume justifies this production system. The equipment is set up in a line or product configuration. All outputs follow the same path due to the standardization of both the processes and the products.
Characteristics
Under the following conditions, mass production is used:
- Standardization of product and process sequence.
- Special-purpose machines with increased production capacities and output rates.
- Large volume of products.
- Shorter cycle time of production.
- Lower in-process inventory.
- Perfectly balanced production lines.
- The flow of materials, components, and parts is continuous and uninterrupted.
- Production planning and control is easy.
- Material handling can be completely automatic.
Here are some examples of mass production:
- Automobile Manufacturing: Automobile manufacturers use assembly lines and automated procedures to build vast numbers of vehicles. High volumes of the same car type are produced using standardized parts.
- Consumer Electronics: Smartphones, tablets, and other electronic devices are mass produced by businesses like Apple, Samsung, and Sony using standardized designs and parts.
- Fast Food Chains: Fast-food establishments like McDonald’s and Burger King use effective cooking and assembly techniques to generate vast amounts of standardized meal items.
- Beverage Bottling: Automated bottling lines are used by businesses like Coca-Cola and PepsiCo to mass produce bottled beverages like sodas and bottled water.
- Clothing Industry: Clothing manufacturers use standardized designs and mechanized sewing machines to mass-create clothes like T-shirts, jeans, and basic attire.
- Appliance Manufacturing: Assembly lines and automated procedures are used by businesses that make goods like refrigerators, washing machines, and microwaves for mass production.
- Toy Manufacturing: Toy manufacturers use automated molding, assembling, and packaging procedures to make vast volumes of toys.
- Furniture Production: Simple chairs and tables, for example, are manufactured in large quantities using automated woodworking equipment and standardized designs.
- Packaged Food Production: Mass production techniques are employed by businesses that produce packaged foods, such as cereal, canned goods, and snacks, to effectively create standardized commodities.
- Pharmaceuticals: Pharmaceutical businesses use automated equipment and stringent quality control to mass-produce drugs in regulated dosages.
- Construction Materials: Using automated manufacturing techniques, products like bricks, concrete blocks, and roofing tiles are produced in large quantities.
- Personal Care Products: Products like toothpaste, soap, and shampoo are mass-produced utilizing automated filling and packaging machinery and standardized formulations.
- Paper and Printing: Using printing machines and automated binding procedures, newspapers, books, and magazines are mass-produced.
- Household Goods: Plastic utensils, containers, and cleaning supplies are mass-produced utilizing automated techniques such as injection molding.
- Canned Foods: Cleaning, cutting, heating, and canning are only a few of the automated procedures used in the industrial production of canned vegetables, fruits, and other goods.
Continuous Production
The production facilities are organized in the order of the production operations, beginning with the first operation and ending with the finished product. Material handling devices such as conveyors, transfer devices, and so on are used to move the items through the sequence of operations.
Characteristics
Continuous production is used in the following situations:
- Dedicated plant and equipment with zero flexibility.
- Material handling is fully automated.
- Process follows a predetermined sequence of operations.
- Component materials are not easily identifiable with the finished product.
- Planning and scheduling is a routine action.
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