Assignment 1

Prof. Gaur A.V.
, BMIT
Assignment 1
Study of Different Manufacturing Systems.

Classification of production system
The production activities are classified according to the volume of production

• Job Shop Production
• Batch Intermittent Production
•. Mass production system
• Continuous production system
1) Job Shop Production system

Job Shop Production/ industries are characterized by manufacturing of one or few quantity
Of products designed and produced as per the specification of customers within prefixed time
and cost. The distinguishing feature of job shop is low volume and high variety of products
Examples of products manufactured by job shop industry include space vehicles, aircraft,
machine tools, special purpose machines, tooling and jigs and fixtures, custom clothing,
prototypes, large turbo generators, material handling machines, construction equipments. A
job shop typically comprises of general-purpose machines arranged in to different
departments. Each job demands an unique technological requirements, demands processing
on machines in a certain sequence. Because of high variety, scheduling becomes complicated.
.
Characteristics of Job Order Production
1. High variety of products and low volume.
2. Use of general purpose machines and facilities.
3. Highly skilled operators who Can take up each job as a challenge
4. Frequently changing set ups,
5, Process (or functional) type layouts for arrangement of facilities.
6. Large inventory of materials, tools and parts.
7. Movement of material is long and interrupted.
Advantages of Job Order production
• Because of general- purpose facilities, variety of products can be processed.
• Operators will become more skilled
• Utilisation of full potential of operators.
• Opportunity to use innovative and creative methods.
Limitations
1. Higher set up and tooling up cost due to frequent set up changes.
2. High inventory level of raw material and in process and hence higher inventory costs.
3. Production planning is complicated.
4. Highly competent and skilled manpower is demanded.
5. Product cost comes to be high.
1
Prof. Gaur A.V. , BMIT
2 ) Batch Production system
Batch production is characterized by the manufacture of limited number of products

produced at regular intervals and stocked awaiting sales. Material tends to be more complex.
Batch production is justified when the production rate exceeds the demand rate. The
quantities in batch production are decided ·based on the balancing of two costs i.e. set up cost
and inventory carrying cost.
Characteristics of Batch Production

1. Shorter production runs.
2. Plant and machinery set up is used for the production of items in a batch and set up
required
3. to be changed for processing next batch of items.
4. More number of set ups and hence higher set up cost.
5. Amount of supervision required is less compared to job order.
6. Plant and machinery are flexible. .
Advantages of Batch Production

• Better utilisation of plant and machinery.
• Promotes functional specialisation.
• Cost per unit is lower as compared to job order production.
• Lower investment in plant and machinery.
• Flexibility to accommodate and process number of products.
Limitations of Batch Production
• Material handling is complex because of irregular and longer flows.
• Production planning and control is complex.
• Work in process inventory is higher compared to continuous production.
• Longer production times.
• Higher set up costs due to frequent up.
3) Mass Production system
Manufacture of discrete parts or assemblies using a continuous process are called Mass
production or Repetitive production. The volumes are very large. The machineries are
arranged in a line or product layout. Specialised departments will disappear and their place is
taken by assembly line. Material handling systems can automated, thus bringing down the
cost of material handling per it. Automobile assembly line is a typically example of mass
production.
Characteristics of Mass Production
1. standardization of product and process sequence and hence line layout (product
layout)
2. is recommended.
3. Dedicated, special purpose machines (SPM) having higher production capabilities and
4. output rates.
2
Prof. Gaur A.V. , BMIT
5. Large volumes of products.

6. Shorter cycle time of production.
Advantages of Mass Production
1. Higher rate of production with reduced cycle time.
2. Higher capacity utilization 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 economics of scale.
Limitations of Mass Production
1. Breakdown of one machine will stop an entire production line.
2. Line layout needs major adjustments/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 .
4) PROCESS INDUSTRIES (Flow Production or Continuous Process Production)

Process manufacturing is defined as the production that adds value by mixing, separating,
forming and/or performing chemical reactions. It may be carried out in either batch or
continuous
mode .
Characteristics of Process Industry (Flow Production)
1. Dedicated plant and equipments with zero flexibility.

2. Material handling is fully automated.
3. Shorter lead-times.
4. Larger investment and usually capital-intensive units.
5. Process follows a predetermined sequence of operations.
6. Unit cost is lower due to high volume.

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Prof. Gaur A.V.

Study of Different Manufacturing Systems.

The production activities are classified according to the volume of production

1) Job Shop Production system

2 ) Batch Production system

Batch production is characterized by the manufacture of limited number of products

Characteristics of Batch Production

Advantages of Batch Production

3) Mass Production system

5. Large volumes of products.

4) PROCESS INDUSTRIES (Flow Production or Continuous Process Production)

Characteristics of Process Industry (Flow Production)

1. Dedicated plant and equipments with zero flexibility.

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