Classification of Production Systems

CLASSIFICATION OF PRODUCTION SYSTEMS
 Production systems can be classified as

1. Job-shop,
2. Batch,
3. Mass and
4. Continuous production systems.
Job-Shop Production: - Are characterized by manufacturing one or few quantities of

products designed and produced as per the specification of customers within prefixed time and
cost.
1. Job-shop Production is characterized by:
1. High variety of products and low volume.
2. Use of general-purpose machines and facilities.
3. Highly skilled operators needed
4. Large inventory of materials, tools, parts.
5. Detailed planning
Advantages of Job-shop Production:
1. Because of general purpose machines and facilities variety of products can be produced.
2. Operators will become more skilled and competent, as each job gives
them learning opportunities.
3. Full potential of operators can be utilized.
4. Opportunity exists for Creative methods and innovative ideas.
Limitations of Job-shop Production:
1. Higher cost due to frequent set up changes.
2. Higher level of inventory at all levels and hence higher inventory cost.
3. Production planning is complicated.
4. Larger space requirements.
2. Batch Production:- Batch Production as a form of manufacturing in which the

job pass through the functional departments in lots or batches and each lot may
have a different routing.
Batch Production is characterized by
1. Shorter production runs.
2. Plant and machinery are flexible.
3. Plant and machinery set up is used for the production of item in a batch
and change of set up is required for processing the next batch.
4. Manufacturing lead-time and cost are lower as compared to job order
production.
Advantages
Following are the advantages of Batch Production:
1. Better utilization of plant and machinery.
2. Promotes functional specialization.
3. Cost per unit is lower as compared to job order production.
4. Lower investment in plant and machinery.
5. Flexibility to accommodate and process number of products.
6. Job satisfaction exists for operators.
Limitations
Following are the limitations of Batch Production:
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. Higher set up costs due to frequent changes in set up.
Mas Production
Manufacture of discrete parts or assemblies using a continuous process are called
Mass Production. This production system is justified by very large volume of
production.
Mass Production is characterized by
1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production
capacities and 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 and without any
back tracking.
8. Production planning and control is easy.
9. Material handling can be completely automatic.
Advantages
Following are the advantages of Mass Production:
1. Higher rate of production with reduced cycle time.
2. Higher capacity utilization due to line balancing.
3. Less skilled operators are required.
4. Low process inventory.
5. Manufacturing cost per unit is low.
Limitations
Following are the limitations of Mass Production:
1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major change with the changes in the product design.
3. High investment in production facilities.
4. The cycle time is determined by the slowest operation.
Continuous Production
Production facilities are arranged as per the sequence of production operations from the first
operations to the finished product. The items are made to flow through the sequence of
operations through material handling devices such as conveyors, transfer devices, etc.
Continuous Production is characterized by
1. Dedicated plant and equipment with zero flexibility.
2. Material handling is fully automated.
3. Process follows a predetermined sequence of operations.
4. Component materials cannot be readily identified with final product.
5. Planning and scheduling is a routine action.
Advantages
Following are the advantages of Continuous Production:
1. Standardization of product and process sequence.
2. Higher rate of production with reduced cycle time.
3. Higher capacity utilization due to line balancing.
4. Manpower is not required for material handling as it is completely
automatic.
5. Person with limited skills can be used on the production line.
6. Unit cost is lower due to high volume of production.
Limitations
Following are the limitations of Continuous Production:
1. Flexibility to accommodate and process number of products does not exist.
2. Very high investment for setting flow lines.
3. Product differentiation is limited.

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CLASSIFICATION OF PRODUCTION SYSTEMS

 Production systems can be classified as

Job-Shop Production: - Are characterized by manufacturing one or few quantities of

2. Batch Production:- Batch Production as a form of manufacturing in which the

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